Service Manual

ManualsBrandsLexmark ManualsPrinterT650

Lexmark

™

T650, T650n, T652dn,

T654dn & T656dne Printer

4062-XXX

• Table of contents

• Start diagnostics

• Safety and notices

• Trademarks

•Index

Lexmark and Lexmark with diamond design are

trademarks of Lexmark International, Inc., registered

in the United States and/or other countries.

Edition: September 17, 2009

Summary of content (588 pages)

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Edition: September 17, 2009 Lexmark™ T650, T650n, T652dn, T654dn & T656dne Printer 4062-XXX • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index 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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4062-XXX Edition: September 17, 2009 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.
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4062-XXX Table of contents Table of contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv Lithium warning . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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062-XXX Sensor (pass through) lingering jam service check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-146 Sensor (pass through) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-147 Sensor (stapler pass through) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-148 Sensor (stapler pass through) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX INPUT TRAY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feed Tests (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensor Test (input tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OUTPUT BIN TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX Wiper Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Clear Custom Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28 Best Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29 Exit Config Menu (models T650, T652, and T654) . . . . . .
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4062-XXX Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Configuration menu (CONFIG MENU) (model T656) . . . . . . . . . . . . . . . .
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4062-XXX Polygon printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-69 Oscillating printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-71 Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-72 Fuser components . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91 Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91 Detection of media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-91 Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX Duplex guide assembly, front removal (T652, T654) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21 Fuser access door assembly removal (T650, T652, T654) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Fuser drive release linkage removal (T650, T652, T654) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23 Fuser unit assembly removal (T650, T652, T654) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX Option removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83 5-bin mailbox rear door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84 5-bin mailbox left outer cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 5-bin mailbox left inner cover removal . . . . . . . . . . . . . . . . . . . . .
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4062-XXX High capacity stacker sensor (deflector gate HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-147 Installing / Removing the RFID UHF option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-148 Lower interface cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-156 Media size actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Individual maintenance part expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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4062-XXX xiv Service Manual
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4062-XXX Notices and safety information The following laser notice labels may be affixed to this printer. Laser notice The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC 60825-1. Class I laser products are not considered to be hazardous.
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4062-XXX Avisos sobre el láser Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1) establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de Clase I (1). Los productos láser de Clase I no se consideran peligrosos.
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4062-XXX Laserilmoitus Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi. Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan 5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla.
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4062-XXX Avís sobre el Làser Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe I que compleix els requisits d’IEC 60825-1. Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb (3b) d’arseniür de gal.li, nominalment de 5 mil.
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4062-XXX Notices and safety information xix
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4062-XXX xx Service Manual
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4062-XXX Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Safety information • The safety of this product is based on testing and approvals of the original design and specific • • • components. The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.
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4062-XXX Sicherheitshinweise • Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und • • • bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine Verantwortung oder Haftung für die Sicherheit übernommen. Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
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4062-XXX Informació de Seguretat • La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components • • • específics. El fabricant no es fa responsable de les qüestions de seguretat si s'utilitzen peces de recanvi no autoritzades. La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està destinada a ningú que no ho sigui.
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4062-XXX Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: 1. General information contains a general description of the printer and the maintenance approach used to 2. 3. 4. 5. 6. 7. repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
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4062-XXX 1. General information The Lexmark™ laser printers are letter-quality page printers designed to attach to personal computers and to most computer networks.
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4062-XXX Options Available internal options • Memory cards — Printer memory — Flash memory — Fonts • Firmware cards — Bar Code and Forms — IPDS and SCS/TNe — PrintCryptionTM — PRESCRIBE • Printer hard disk • Lexmark™ Internal Solutions Ports (ISP) — RS-232-C serial interface ISP — Parallel 1284-B interface ISP — MarkNetTM N8150 802.11 b/g/n Wireless ISP — MarkNet N8130 10/100 Thick Fiber ISP — MarkNet N8120 10/100/1000 Thick Ethernet ISP • MarkNet N8110 v.34 Fax Card The following options are available.
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4062-XXX Printer configurations Basic model The following illustration shows the basic printer model. 1 2 3 4 Feature 1 Standard exit bin 2 Printer control panel 3 Multipurpose feeder 4 Standard tray (Tray 1) 1Based on 75 g/m2 (20 lb.) paper.
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4062-XXX Fully configured model The following illustration shows the fully configured printer model. CAUTION: –TIPPING HAZARD: Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a 2000-sheet tray, a duplex unit, and an input option, or more than one input option. For more information, see www.lexmark.com/publications/furniture_safety.
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4062-XXX Feature/Option 1 2 3 2 5-bin mailbox Output expander3 Envelope feeder (Not for use with the T656dne) 4 Standard tray (Tray 1) 5 Duplex unit4 6 Optional tray (Tray 2) 7 Optional tray (Tray 3) 8 Optional 2000-sheet tray (Tray 4) 9 Caster base 1 Based on 75 g/m2 (20 lb.) paper. 2 Paper Capacity1 500 sheets 550 sheets 85 envelopes 250 or 550-sheets Not applicable 250- or 550-sheets 250- or 550-sheets 2000 sheets Not applicable Up to two 5-bin mailbox units are supported.
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4062-XXX Supported paper sizes, types, and weights The following tables provide information on standard and optional paper sources and the types of paper they support. Note: For an unlisted paper size, select the closest larger listed size. Paper sizes supported by the printer 250-or 550-sheet trays (standard or optional Paper size Dimensions A4 210 x 297 mm (8.3 x 11.7 in.) x A5 148 x 210 mm (5.8 x8.3in.) x A61,2 105 x 148 mm (4.1 x 5.8 in.) J15 B5 182 x 257 mm (7.2 x 10.1 in.
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4062-XXX 250-or 550-sheet trays (standard or optional Paper size Dimensions Other Envelope 98 x 162 mm (3.9 x 6.4 in.) to 176 x 250 mm (6.9 x 9.8 in.) Optional 2000-sheet tray Multipurpose feeder Duplex unit x 1This size appears in the Paper Size menu only when the paper source does not support size sensing or when size sensing is turned off. 2Only the standard exit bin supports this size. 3This size setting formats the page for 216 x 356 mm (8.5 x 14 in.
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4062-XXX The finisher supports 60-176 g/m2 (16-47 lb) paper weights.
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4062-XXX Acronyms BLDC CRU CSU DIMM DRAM DVM EDO EEPROM EP EPROM ESD FRU GB HCIT HVPS ITC LASER LCD LED LVPS MPF MROM MS NVRAM OEM OPT PC pel POR POST PP PWM RFID RIP ROM SDRAM SIMM SRAM UAT UPR V ac V dc VOM Brushless DC motor Customer Replaceable Unit Customer setup Dual Inline Memory Module Dynamic Random Access Memory Digital multimeter Enhanced Data Out Electrically Erasable Programable Read-Only Memory Electrophotographic process Erasable Programmable Read-Only Memory Electrostatic Discharge Field R
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4062-XXX 1-10 Service Manual
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4062 2. Diagnostic information Start CAUTION: Unplug the power cord from the electrical outlet before you connect or disconnect any cable electronic board or assembly. CAUTION: If the printer is kept on, never touch the conductive parts if not specifically required. The power switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while the power supply is cut off. Never touch the live parts. CAUTION: Be careful to avoid burns by safely handling hot parts.
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4062 Confirm the installation status Be sure to check the following items before starting the troubleshooting procedures. • With the power cord unplugged from the wall outlet, check that the cord is free from breakage, short-circuit, disconnected wire, or incorrect connection in the power cord. • The printer is properly grounded. Check the power cord ground terminal. • The printer is not installed at a place subjected to extreme temperature, extreme humidity or rapid changes in temperature.
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4062 User attendance messages Error code or message Error contents Description/Action Possible repair actions System Timeout System Timeout The system detects a firmware component that is no longer responding. Turn the power off; wait a few seconds, and then turn the power back on. 30.XX Invalid Refill Change Cartridge Message is cleared when a new print cartridge is installed. Install the proper print cartridge. 31.
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4062 Error code or message 35 Error contents Res Save Off Deficient Memory Description/Action Possible repair actions This IR is displayed when the printer lacks sufficient memory to enable Resource Save. This message usually indicates the user has allocated too much memory for one or more of the printer's link buffers; however, modification of other printer settings which affect the amount of available memory may also create this condition.
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4062 Error code or message 37 Error contents Insufficient Memory Description/Action This message displays when the printer memory used to restore the Print and Hold jobs from the disk and found that some or all of the jobs could not be restored. The printer ran out of memory while attempting to restore the jobs. Possible repair actions The following actions may be taken: • Press to clear the message. Some of the Print and Hold jobs on the disk will not be restored.
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62 Error code or message 44.01 Error contents RFID Error Description/Action Bad tag error: a tag has failed to program, or the “Retry Count” has been exceeded. Note: This error is not a data parsing error, but indicates bad RFID media. It is posted only if the “Stop on Error” menu setting is set to “ON”. 44.11 RFID Error Generic parse error 44.12 RFID Error Subcommand appears truncated 44.13 RFID Error Subcommand appears longer than expected 44.
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4062 Error code or message Error contents Description/Action Possible repair actions 44.26 RFID Error Based on tag location parameters: tag is not compatible with printer 1. These error codes most likely indicate a problem with the customer’s datastream, and not the RFID Option itself. Ensure there is nothing wrong with the customer’s datastream. 2. Check the RFID firmware card, RFID interface card, RFID cable, and RFID option for correct installation.
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4062 Error code or message Error contents Description/Action 44.36 RFID Error Invalid X/Y Position 42.XY Cartridge Region Mismatch This IR is displayed when the printer detects that the installed cartridge has a region that differs from the below options. To clear this IR, the printer cartridge must be replaced with one that has a proper region. Possible repair actions 1. This error code most likely indicates a problem with the customer’s datastream, and not the RFID Option itself.
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4062 Error code or message Error contents Description/Action Possible repair actions 52 Flash Full This message displays when the printer detects an unformatted flash at power on. Press to clear the message. The flash is marked as bad and normal operation continues. Flash operations are not allowed until the flash is formatted. 54 Serial Option [x] Error This IR is displayed when a serial error (framing, parity or overrun) has been detected on the specified optional serial port.
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4062 Error code or message 56 56 Error contents Description/Action Possible repair actions Serial Port [x] Disabled This error displays when data is sent to the printer across an serial port, but the port has been disabled. Once this message displays, reporting of further errors is suppressed until the menus are entered, or the printer is reset. Go to network service check. Standard USB Port Disabled Displayed when status is requested over the USB port, but the port has been disabled.
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4062 Error code or message Error contents Description/Action Possible repair actions 58 Too Many Disks Installed This error code displays when too many disks are attached to the printer. 1. Turn off and unplug the printer. 2. Remove the excess disks. 3. Plug in the printer, and turn it on. 58 Too Many Flash Options This error code displays when too many user flash memory options or too many optional firmware cards have been installed. 1. Turn off and unplug the printer. 2.
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4062 Error code or message Error contents Description/Action Possible repair actions 59 Incompatible Output Bin [x] An incompatible output bin is installed. For Output Bin x, x=1, 2, or 3. Remove the incompatible output bin and press to clear the message. Note: If the user installed the incompatible device to satisfy a Check Device Connections/ reattach message, the user should reinstall an associated compatible option or hot unplug the option. 1. Turn off and unplug the printer. 2.
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4062 Error code or message Error contents Description/Action Possible repair actions 88 Cartridge Low This IR is displayed when cartridge low occurs and the cartridge low alarm is activated. If cartridge alarm is not activated, this is not an intervention condition. Replace the print cartridge. 88 Cartridge Nearly Low This IR is displayed when cartridge low occurs and the cartridge low alarm is activated. If cartridge alarm is not activated, this is not an intervention condition.
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4062 Error code table 1 Error code or message 200.00 Error contents Sensor (input) area jam Description/Action The media is jammed in the sensor (input) area. Possible repair actions 1. Fan the media and check for obstructions. 2. Go to sensor (input) service check. See “Sensor (input) service check” on page 2-126. 200.01 Sensor (input) lingering jam Source = MPF, duplex or envelope feeder The media reached the sensor (input) but did not clear it within the specified time. 1.
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4062 Error code or message Error contents Description/Action Possible repair actions 200.09 Printhead laser start failure The printhead laser start process failed because it did not receive proper feedback signal from the printhead motor. 1. Check all connections on the printhead. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly if problem remains. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 200.
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4062 Error code or message 200.13 200.14 Error contents Sensor (input) static jam Sensor (input) early jam Description/Action Possible repair actions Media remains on the sensor (input) during the warm up sequence. Go to sensor (input) static jam service check. The media reached the sensor (input) sooner than the specified time. Go to sensor (input) early jam service check. See “Sensor (input) static jam service check” on page 2-135. See “Sensor (input) early jam service check” on page 2-133.
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4062 Error code or message 200.19 Error contents Sensor (input) lingering jam Source = Tray 1 Tray level = Empty 200.27 Sensor (input) lingering jam Source = Tray 2 Tray level = Not Low 200.28 Sensor (input) lingering jam Source = Tray 2 Tray level = Low 200.29 Sensor (input) lingering jam Source = Tray 2 Tray level = Empty 200.32 Operator panel door assembly switch failure 200.
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4062 Error code or message 200.38 Error contents Sensor (input) lingering jam Source = Tray 3 Tray level = Low 200.39 Sensor (input) lingering jam Source = Tray 3 Tray level = Empty 200.47 Sensor (input) lingering jam Source = Tray 4 Tray level = Not Low 200.48 Sensor (input) lingering jam Source = Tray 4 Tray level = Low 200.49 Sensor (input) lingering jam Source = Tray 4 Tray level = Empty 200.57 Sensor (input) lingering jam Source = Tray 5 Tray level = Not Low 200.
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4062 Error code or message 201.01 Error contents Main drive motor assembly load error. Type 1 fuser 201.02 Sensor (fuser output) late jam. Type 1 fuser Description/Action Possible repair actions The main drive motor assembly has failed or caused high mechanical load due to paper jam or bind. 1. Check all connections on the main drive motor assembly. 2. Check all connections on the system card assembly. 3. Replace the main drive motor assembly if problem remains.
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4062 Error code or message 201.26 Error contents Main drive motor assembly load error. Type 2 fuser 201.27 Sensor (fuser output) late jam. Type 2 fuser Description/Action Possible repair actions The main drive motor assembly has failed or caused high mechanical load due to paper jam or bind. 1. Check all connections on the main drive motor assembly. 2. Check all connections on the system card assembly. 3. Replace the main drive motor assembly if problem remains.
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4062 Error code or message 201.32 Error contents Description/Action Possible repair actions Sensor (fuser output) late jam The media is late reaching the sensor (fuser output) within the specified time. Go to sensor (fuser output) late jam service check. The media is late reaching the sensor (fuser output) within the specified time. Go to sensor (fuser output) service check. Type 2 fuser 201.50 Sensor (fuser output) late jam Type 1 fuser Fuser page count has exceeded life. 201.
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4062 Error code or message 201.55 Error contents Operator panel door assembly interlock switch open failure Type 1 fuser Description/Action Possible repair actions The printer detected that the switch (operator panel door interlock) did not cycle prior to printer restart. 1. Remove all media present in media path. 2. Ensure that the operator panel door assembly is fully open then fully closed. 3. Check operator panel door assembly for damage. 4.
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4062 Error code or message 201.78 Error contents Image data did not start in time Description/Action Printhead write failure Type 2 fuser Possible repair actions 1. Check all connections on the printhead assembly 2. Check all connections on the system card assembly. Fuser page count has exceeded life 3. Replace the printhead assembly if problem remains. 4. Replace the system card assembly if problem remains. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 201.
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4062 Error code or message 202.00 Error contents Paper jam around fuser exit or redrive area. Description/Action Possible repair actions Page may be jammed in fuser exit or redrive area. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4. Go to sensor (fuser output) service check. See “Sensor (fuser output) service check” on page 2-126. 5. Go to sensor (narrow media) service check.
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4062 Error code or message 202.10 Error contents Description/Action Sensor (fuser output) lingering jam. Media reached the sensor (fuser output) but did not clear it in the specified time. Destination is output option. 202.11 Type 1 fuser Media did not reach the sensor (narrow media) Sensor (fuser output) lingering jam. Media reached the sensor (fuser output) but did not clear it in the specified time. Destination is standard bin. 202.
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4062 Error code or message 202.27 Error contents Description/Action Sensor (fuser output) lingering jam. Media reached the sensor (fuser output) but did not clear it in the specified time. Go to sensor (fuser output) lingering jam service check. Media remains on the sensor (narrow media) during the warm up sequence. Go to sensor (narrow media) static jam service check. The sensor (fuser output) rebounded once the trailing edge of the media passed. Go to sensor (fuser output) service check.
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4062 Error code or message 202.37 Error contents Description/Action Sensor (fuser output) lingering jam. Media reached the sensor (fuser output) but did not clear it in the specified time. Destination is output option. 202.38 and See “Sensor (fuser output) lingering jam service check.” on page 2-137. Media did reach the sensor (narrow media) Sensor (fuser output) static jam Media remains on the sensor (fuser output) and the sensor (narrow media) during the warm up sequence. 1.
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4062 Error code or message 202.54 Error contents Sensor (fuser output) bounce Type 1 fuser Description/Action The sensor (fuser output) rebounded once the trailing edge of the media passed. Go to sensor (fuser output) service check. Media remains on the sensor (fuser output) during the warm up sequence. Go to sensor (fuser output) static jam service check. Media reached the sensor (fuser output) but did not clear it in the specified time. Go to sensor (fuser output) lingering jam service check.
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4062 Error code or message 202.63 Error contents Sensor (fuser output) static jam and Description/Action Media remains on the sensor (fuser output) and the sensor (narrow media) during the warm up sequence. 1. Go to sensor (fuser output) static jam service check. See “Sensor (fuser output) static jam service check” on page 2-138. 2. Go to sensor (narrow media) static jam service check. See “Sensor (narrow media) static jam service check” on page 2-140.
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4062 Error code or message 202.81 Error contents Description/Action Sensor (fuser output) static jam Media remains on the sensor (fuser output) during the warm up sequence. Go to sensor (fuser output) static jam service check. Media reached the sensor (fuser output) but did not clear it in the specified time. Go to sensor (fuser output) lingering jam service check. Media reached the sensor (fuser output) but did not clear it in the specified time.
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4062 Error code or message 202.99 Error contents Fuser ID chip failure Description/Action The system does not recognize the ID chip on the fuser unit. Possible repair actions Replace the fuser unit assembly. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23, 203.00 Paper jam around redrive area. Page may be jammed in redrive area. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4.
PAGE 66
4062 Error code or message 203.10 Error contents Redrive motor control failure. Media tray 1 Description/Action Possible repair actions The redrive motor does not reach the proper operating speed at the specified time. 1. Remove all media present in media path. 2. Ensure that upper redive assembly is properly installed. 3. Check all connections on the redrive motor assembly. 4. Check all connections on the system card assembly. 5. Replace the redrive motor assembly if problem remains.
PAGE 67
4062 Error code or message 230.02 Error contents Description/Action Possible repair actions Sensor (duplex input) late jam Media is late reaching the sensor (duplex input) within the specified time. Go to sensor (duplex input) late jam service check. The sensor (duplex input) rebounded once the trailing edge of the media passed. Go to sensor (duplex input) service check. See “Sensor (duplex input) service check” on page 2-127.
PAGE 68
4062 Error code or message 230.10 Error contents Internal duplex drive motor control failure. Source = Internal duplex 230.13 sensor (duplex input) static jam Source = Internal duplex 230.14 Paper jam around internal duplex. Description/Action Possible repair actions The internal duplex drive motor motor does not reach the proper operating speed at the specified time. 1. Remove all media present in media path. 2. Check all connections on the duplex media entrance drive motor assembly. 3.
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4062 Error code or message 230.20 Error contents Internal duplex drive motor lost encoder failure Description/Action Possible repair actions The internal duplex drive motor is not reporting pulses back to the engine. 1. Remove all media present in media path. 2. Check all connections on the duplex media entrance drive motor assembly. 3. Check all connections on the system card assembly. 4. Replace the duplex drive motor assembly if problem remains.
PAGE 70
4062 Error code or message 234.00 Error contents Sensor (duplex exit) late jam Source = External duplex 235.00 Sensor (duplex double-feed) lingering jam Source = External duplex 236.00 Sensor (duplex exit) lingering jam Source = External duplex 237.00 Sensor (input) late jam from duplex Source = External duplex 2-36 Service Manual Description/Action Possible repair actions Media is late reaching the sensor (duplex exit) within the specified time. 1. Remove all media present in media path. 2.
PAGE 71
4062 Error code or message 237.07 Error contents Paper jam around external duplex Description/Action Page may be jammed in external duplex area. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4. Ensure the external duplex assembly is properly installed. 5. Ensure the rear door of the external duplex is fully closed. 6. Ensure the external duplex tray is fully closed. 7. Ensure the media tray 1 is fully closed. 8.
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4062 Error code or message 238.04 Error contents Sensor (duplex double-feed) static jam Description/Action Possible repair actions Media remains on the sensor (duplex double-feed) during the warm up sequence. 1. Remove all media present in media path. 2. Replace the external duplex assembly if problem remains. Media remains on the sensor (duplex input) and the sensor (double-feed) during the warm up sequence. 1. Remove all media present in media path. Source = External duplex 238.
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4062 Error code or message 239.01 Error contents External duplex assembly error Description/Action Possible repair actions Mechanical feed error or timing error. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4. Ensure the external duplex assembly is properly installed. 5. Ensure the rear door of the external duplex is fully closed. 6. Check all connections on the external duplex assembly. 7.
PAGE 74
4062 Error code or message 239.04 Error contents Input device ready response error. Description/Action Possible repair actions Mechanical feed error or timing error. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4. Ensure the external duplex assembly is properly installed. 5. Ensure the rear door of the external duplex is fully closed. 6. Check all connections on the external duplex assembly. 7.
PAGE 75
4062 Error code or message 239.07 Error contents Select output device error. Description/Action Possible repair actions Mechanical feed error or timing error. 1. Remove all media present in media path. 2. Check media for proper installation. 3. Check for obstructions in media path. 4. Ensure the external duplex assembly is properly installed. 5. Ensure the rear door of the external duplex is fully closed. 6. Check all connections on the external duplex assembly. 7.
PAGE 76
4062 Error code or message 241.01 Error contents Pick motor control failure. Media tray 1 241.06 Sensor (input) late jam Source = Tray 1 or MPF 241.07 Pick motor load error Source = Media tray 1 2-42 Service Manual Description/Action Possible repair actions The pick motor does not reach the proper operating speed at the specified time. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4.
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4062 Error code or message 241.08 Error contents Pick motor load error Source = Media tray 1 241.10 Sensor (input) late jam Source = Tray 1 241.11 Sensor (input) late jam Source = Tray 1 241.12 Sensor (input) late jam Source = Tray 1 or envelope feeder 241.14 Sensor (input) late jam Source = Tray 1 or envelope feeder 241.15 Sensor (input) late jam Source = Tray 1 or envelope feeder Description/Action The pick motor has failed or caused high mechanical load due to paper jam or bind.
PAGE 78
4062 Error code or message 241.16 Error contents Sensor (input) late jam Source = Tray 1 241.18 Sensor (input) late jam Source = Tray 1 241.19 Pick motor control failure. Source = Tray 1 241.20 Tray 1 pick motor lost encoder failure Description/Action The media is late reaching the sensor (input) within the specified time. Go to sensor (input) late jam service check. The media is late reaching the sensor (input) within the specified time. Go to sensor (input) late jam service check.
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4062 Error code or message 242.03 Error contents Description/Action Sensor (pass through) late jam The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check.
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4062 Error code or message 242.18 Error contents Pick retry timeout Source = Tray 2 242.19 Pick retry timeout Source = Tray 2 242.52 Tray 2 pick motor overrun failure Source = Tray 2 242.33 Tray 2 not ready Source = Tray 2 242.34 Empty tray pick attempted Description/Action The engine timed out waiting for the tray 2 to report ready before the first pick attempt. Turn the machine off/on. The engine timed out waiting for the tray 2 to report ready before a pick retry attempt.
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4062 Error code or message Error contents Description/Action Possible repair actions 242.39 Media tray pulled jam A media tray above the source tray was pulled during the printing process. 1. Remove all media present in media path. 2. Close all media trays. 242.40 Sensor (pass through) lingering jam Media reached the sensor (pass through) within the specified time but did not clear it within the specified time. Go to sensor (pass through) lingering jam service check.
PAGE 82
4062 Error code or message 242.65 242.66 Error contents Pick motor load error Possible repair actions Source = Media tray 2 The pick motor has failed or caused high mechanical load due to paper jam or bind. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check, clean or replace the pick rolls for wear and excess contamination. Go to “Pick roll assembly removal (T650, T652, T654)” on page 4-57. 4. Check all connections on the pick arm assembly. 5.
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4062 Error code or message 242.67 Error contents Description/Action Possible repair actions Pick motor overspeed failure The pick motor does not rotate at the specified speed. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
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4062 Error code or message 242.69 Error contents Pick motor control failure. Source = Media tray 2 Description/Action Possible repair actions The pick motor does not reach the proper operating speed at the specified time. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
PAGE 85
4062 Error code or message 243.08 Error contents Description/Action Sensor (pass through) lingering jam Media reached the sensor (pass through) within the specified time but did not clear it within the specified time. Go to sensor (pass through) lingering jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. Media remains on the sensor (input) during the warm up sequence.
PAGE 86
4062 Error code or message 243.35 Error contents Pick page received while POR not yet done. Description/Action Media remains on the sensor (input) during the warm up sequence. Go to sensor (pass through) static jam service check. Media remains on the sensor (input) during the warm up sequence. Go to sensor (pass through) static jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. Source = Tray 3 243.
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4062 Error code or message 243.52 Error contents HCIT tray lift motor overrun failure Source = Tray 3 Description/Action Possible repair actions The HCIT tray lift motor continues to detect pulses after the motor has turned off. 1. Ensure the HCIT media tray assembly is properly inserted into the machine. 2. Check the HCIT tray lift motor assembly for binding or damage. 3. Replace the HCIT tray lift drive motor assembly if problem remains.
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4062 Error code or message 243.66 Error contents Pick motor underspeed failure Description/Action Possible repair actions The pick motor does not rotate at the specified speed. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
PAGE 89
4062 Error code or message 243.68 Error contents Description/Action Possible repair actions Pick motor stop error Pick motor stop error detected by options tray x 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. 6.
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4062 Error code or message 244.04 Error contents Description/Action Sensor (pass through) late jam The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check.
PAGE 91
4062 Error code or message 244.33 Error contents Tray 4 not ready Source = Tray 4 244.34 Empty tray pick attempted Description/Action Tray was not properly pushed into the machine. 1. Check the size sensing fingers on the media tray for damage 2. Replace the media tray assembly if problem remains. 3. Check the switch (media size) for proper connection. 4. Replace the switch (media size) if problem remains. Go to “Switch (media size) assembly removal (T650, T652, T654)” on page 4-74.
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4062 Error code or message 244.49 Error contents HCIT tray lift motor stalled failure Source = Tray 4 Description/Action The HCIT tray lift motor has stalled or has become obstructed. Possible repair actions 1. Ensure the HCIT media tray assembly is properly inserted into the machine. 2. Check the HCIT tray lift motor assembly for binding or damage. 3. Replace the HCIT tray lift drive motor assembly if problem remains.
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4062 Error code or message 244.65 244.66 Error contents Description/Action Possible repair actions Source = Media tray 4 The pick motor has failed or caused high mechanical load due to paper jam or bind. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check, clean or replace the pick rolls for wear and excess contamination. Go to “Pick roll assembly removal (T650, T652, T654)” on page 4-57. 4. Check all connections on the pick arm assembly. 5.
PAGE 94
4062 Error code or message 244.67 Error contents Description/Action Possible repair actions Pick motor overspeed failure The pick motor does not rotate at the specified speed. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
PAGE 95
4062 Error code or message 244.69 Error contents Pick motor control failure. Source = Media tray 4 Description/Action Possible repair actions The pick motor does not reach the proper operating speed at the specified time. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
PAGE 96
4062 Error code or message 245.08 Error contents Description/Action Sensor (pass through) lingering jam Media reached the sensor (pass through) within the specified time but did not clear it within the specified time. Go to sensor (pass through) lingering jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. Media remains on the sensor (input) during the warm up sequence.
PAGE 97
4062 Error code or message 245.35 Error contents Pick page received while POR not yet done. Description/Action Media remains on the sensor (input) during the warm up sequence. Go to sensor (pass through) static jam service check. Media remains on the sensor (input) during the warm up sequence. Go to sensor (pass through) static jam service check. The media is late reaching the sensor (pass through) within the specified time. Go to sensor (pass through) late jam service check. Source = Tray 5 345.
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4062 Error code or message 245.52 Error contents HCIT tray lift motor overrun failure Source = Tray 5 Description/Action Possible repair actions The HCIT tray lift motor continues to detect pulses after the motor has turned off. 1. Ensure the HCIT media tray assembly is properly inserted into the machine. 2. Check the HCIT tray lift motor assembly for binding or damage. 3. Replace the HCIT tray lift drive motor assembly if problem remains.
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4062 Error code or message 245.66 Error contents Pick motor underspeed failure Description/Action Possible repair actions The pick motor does not rotate at the specified speed. 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains.
PAGE 100
4062 Error code or message 245.68 Error contents Description/Action Possible repair actions Pick motor stop error Pick motor stop error detected by options tray x 1. Remove all media present in media path. 2. Ensure media tray is not overfilled. 3. Check all connections on the pick arm assembly. 4. Check all connections on the system card assembly. 5. Replace the pick arm assembly if problem remains. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. 6.
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4062 Error code or message 250.07 Error contents Sensor (input) late jam Source = MPF 250.08 Sensor (input) late jam Source = MPF 250.09 Sensor (input) late jam Source = MPF 250.10 Sensor (input) late jam Source = MPF 250.11 Sensor (input) late jam Source = MPF Description/Action Possible repair actions The media is late reaching the sensor (input) within the specified time. Go to sensor (input) late jam service check. The media is late reaching the sensor (input) within the specified time.
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4062 Error code or message Error contents Description/Action Possible repair actions 260.02 Envelope feeder assembly error Mechanical feed error or timing error. 1. Remove the envelope feeder. 2. Remove all media present in media path. 3. Check media for proper installation. 4. Check for obstructions in media path. 5. Ensure the envelope feeder assembly is properly installed. 6. Check all connections on the envelope feeder assembly. 7. Replace the envelope feeder assembly if problem remains. 260.
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4062 Error code or message 260.07 Error contents Sensor (input) late jam Source = Envelope feeder 260.10 Sensor (input) late jam Source = Envelope feeder 260.11 Sensor (input) late jam Source = Envelope feeder 260.12 Sensor (input) late jam Source = Envelope feeder Description/Action Possible repair actions The media is late reaching the sensor (input) within the specified time. Go to sensor (input) late jam service check.
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4062 Error code or message 271.04 x = bin number Error contents Sensor (output pass through) late jam Applies to: Description/Action Possible repair actions The media is late reaching the sensor (output pass through) within the specified time. See “Sensor (output pass through) late jam service check” on page 2-150. The media reached the sensor (output pass through) but did not clear it in the specified time. See “Sensor (output pass through) lingering jam service check” on page 2-151.
PAGE 105
4062 Error code or message 27x.50 x = bin number Error contents Description/Action Sensor (output pass through) lingering jam The media reached the sensor (output pass through) but did not clear it in the specified time. See “Sensor (output pass through) lingering jam service check” on page 2-151. The sensor (left tamper HP) does not detect that the tamper has moved from home position. 1. Check all the connections on the output option controller card.
PAGE 106
4062 Error code or message 27x.53 x = bin number Error contents Sensor (mailbox empty) late jam Applies to: Description/Action Possible repair actions The media is late reaching the sensor (mailbox empty) within the specified time. See “Sensor (mailbox empty) late jam service check” on page 2-153 The media reached the sensor (output pass through) but did not clear it in the specified time. See “Sensor (output pass through) lingering jam service check” on page 2-151.
PAGE 107
4062 Error code or message 28x.30 x = bin number Error contents Description/Action Page ID complete not clear A software failure has occurred with the output option. 1. Turn the machine off/on. The output option transport motor encoder is not detected upon startup. 1. Check all connections on the output option controller card. The transport motor encoder detection is lost during normal operation. 1. Check all connections on the output option controller card.
PAGE 108
4062 Error code or message 28x.36 x = bin number Error contents Stapler drive motor jammed Applies to: Description/Action The stapler assembly has jammed while stapling or the stapler drive motor has failed. Possible repair actions 1. Check all the connections on the controller card and the stapler assembly. 2. Remove the staple cartridge and remove all jammed staples. If the cartridge is jammed and can not be removed, go to step 3. StapleSmart finisher 3. Remove the stapler assembly.
PAGE 109
4062 Error code or message 28x.39 x = bin number Error contents Staple ready home position jam Applies to: StapleSmart finisher Description/Action Possible repair actions The sensor (self priming) within the stapler assembly does not detect a ready staple in the specified time during mechanical reset. 1. Check all the connections on the controller card and the stapler assembly. 2. Remove the staple cartridge and remove all jammed staples.
PAGE 110
4062 Error code or message 28x.41 x = bin number Error contents Left tamper does not move to home position failure. Description/Action Possible repair actions The sensor (left tamper HP) does not detect that the tamper has reached home position. 1. Check all the connections on the output option controller card. Applies to: 2. Check the tamper drive belt for damage and replace if needed. StapleSmart finisher 3. Replace the left tamper motor assembly.
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4062 Error code or message 28x.43 x = bin number Error contents Description/Action Possible repair actions Right tamper does not move to home position failure. The sensor (right tamper HP) does not detect that the tamper has reached home position. 1. Check all the connections on the output option controller card. Applies to: 2. Check the tamper drive belt for damage and replace if needed. StapleSmart finisher 3. Replace the right tamper motor assembly.
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4062 Error code or message 28x.48 x = bin number Error contents Deflector gate transition to output option not detected Applies to: Description/Action Possible repair actions The sensor (deflector gate HP) does not detect transition of the deflector gate to the output option. 1. Check all the connections on the output option controller card. StapleSmart finisher 2. Check the sensor (deflector HP) for damage and replace if needed.
PAGE 113
4062 Error code or message 28x.51 x = bin number Error contents Right tamper home position jam Applies to: Description/Action Possible repair actions The right tamper home position is not detected by the sensor (right tamper HP) 1. Check all the connections on the output option controller card. 2. Check the tamper drive belt for damage and replace if needed. StapleSmart finisher 3. Replace the right tamper motor assembly.
PAGE 114
4062 Error code or message 28x.58 x = bin number 28x.59 x = bin number Error contents Sensor (stapler pass through) late jam StapleSmart finisher Staple ready home position jam Applies to: StapleSmart finisher Description/Action Possible repair actions The media is late reaching the sensor (stapler pass through) within the specified time. See “Sensor (output pass through) late jam service check” on page 2-150.
PAGE 115
4062 Error code or message 28x.64 x = bin number Error contents Bin clamp motor control timer error during tray holder initial. Description/Action Possible repair actions A software failure has occurred with the output option. 1. Turn the machine off/on. The bin clamp home position is not detected by the sensor (bin clamp HP) 1. Turn the machine off/on. The sensor (bin clamp HP) does not detect that the bin clamp has moved from home position. 1. Turn the machine off/on.
PAGE 116
4062 Error code or message 28x.69 x = bin number Error contents Staple ready home position jam Applies to: StapleSmart finisher Description/Action Possible repair actions The sensor (self priming) within the stapler assembly does not detect a ready staple in the specified time after the staple job was sent. 1. Check all the connections on the controller card and the stapler assembly. Staples not empty 2. Remove the staple cartridge and remove all jammed staples.
PAGE 117
4062 Error code or message 28x.71 x = bin number Error contents Description/Action Possible repair actions Deflector gate transition to standard bin not detected The sensor (deflector gate HP) does not detect transition of the deflector gate to the standard bin. 1. Check all the connections on the output option controller card. Applies to: StapleSmart finisher 2. Check the sensor (deflector HP) for damage and replace if needed.
PAGE 118
4062 Error code or message Error contents Description/Action Possible repair actions 902.xx System software error Code detected unusual event or timing. 1. POR the machine and print a simple test page to determine if the problem is system software related, or if the customer is sending a corrupted print job. 2. Check all connections on the system card assembly. 3. Replace the system card assembly if problem remains. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 903.
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4062 Error code or message Error contents Description/Action Possible repair actions 906.xx RIP interface driver error Code detected unusual event or timing. 1. POR the machine and print a simple test page to determine if the problem is system software related, or if the customer is sending a corrupted print job. 2. Check all connections on the system card assembly. 3. Replace the system card assembly if problem remains. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76.
PAGE 120
4062 Error code or message 914.00 Error contents Description/Action Possible repair actions Pick arm motor no encoder not detected failure The pick arm motor encoder detection is lost during normal operation 1. Check all the connections on the pick arm assembly. 2. Check all the connections on the system card assembly. 3. Replace the pick arm assembly if problem remains. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. 914.
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4062 Error code or message 916.01 Error contents Internal duplex drive motor over speed failure Description/Action The duplex drive motor does not rotate at the specified speed. Possible repair actions 1. Check all the connections on the duplex drive motor assembly. 2. Check all the connections on the system card assembly. 3. Replace the duplex drive motor assembly if problem remains. Go to “Duplex drive motor assembly removal (T652, T654)” on page 4-19. 920.
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4062 Error code or message 920.03 Error contents Fuser warm-up failure Fuser type = 1 920.04 Fuser warm-up failure Fuser type = 1 920.06 Fuser warm-up failure Fuser type = 1 2-88 Service Manual Description/Action Possible repair actions The fuser hot roll is too cool while checking for slope change in standby. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3.
PAGE 123
4062 Error code or message 920.07 920.25 Error contents Possible repair actions Fuser type = 1 The fuser hot roll temperature is not maintained properly while the media in the fuser nip. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains.
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4062 Error code or message 920.27 Error contents Fuser warm-up failure Fuser type = 2 920.28 Fuser warm-up failure Fuser type = 2 920.29 Fuser warm-up failure Fuser type = 2 2-90 Service Manual Description/Action Possible repair actions The fuser hot roll fell to far below desired temperature while in standby control. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3.
PAGE 125
4062 Error code or message 920.31 Error contents 920.50 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. 5. Replace the LVPS card assembly if problem remains.
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4062 Error code or message 920.52 Error contents Fuser warm-up failure Fuser type = 1 Description/Action The fuser hot roll fell to far below desired temperature while in standby control. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. The fuser hot roll is too cool while checking for slope change in standby. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23.
PAGE 127
4062 Error code or message 920.81 Error contents Fuser warm-up failure Fuser type = 2 Description/Action The fuser hot roll temperature does not increase while the lamp is turned on. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. The fuser hot roll temperature is not maintained properly while the media in the fuser nip. Replace the fuser unit assembly if problem remains.
PAGE 128
4062 Error code or message 922.03 Error contents Fuser warm-up failure 922.05 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. 5. Replace the LVPS card assembly if problem remains.
PAGE 129
4062 Error code or message 922.06 Error contents Description/Action Possible repair actions Fuser warm-up failure The fuser hot roll did not reach operating temperature within new enhanced control. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains.
PAGE 130
4062 Error code or message 922.25 Error contents Fuser warm-up failure Fuser type = 2 922.27 Fuser warm-up failure Fuser type = 2 2-96 Service Manual Description/Action Possible repair actions The fuser hot roll failed to reach target departure. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Replace the fuser unit assembly if problem remains.
PAGE 131
4062 Error code or message 922.28 Error contents 922.30 Possible repair actions The fuser hot roll does reach the “final lamp detection” parameter but not in the specified time. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains.
PAGE 132
4062 Error code or message 922.31 Error contents Description/Action Possible repair actions Fuser warm-up failure The fuser hot roll did not reach operating temperature within new enhanced control. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Check all connections on the fuser and LVPS card assembly. 4. Replace the fuser unit assembly if problem remains.
PAGE 133
4062 Error code or message 922.53 Error contents Fuser warm-up failure Fuser type = 1 Fuser page count has exceeded life. 922.54 Fuser warm-up failure Fuser type = 1 Fuser page count has exceeded life. 922.56 Fuser warm-up failure Fuser type = 1 Description/Action The fuser hot roll does reach the “final lamp detection” parameter but not in the specified time. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23.
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4062 Error code or message 923.00 Error contents Fuser over temperature failure. Fuser type = 1 923.01 Fuser over temperature failure. Fuser type = 1 923.25 Fuser over temperature failure. Fuser type = 2 923.26 Fuser over temperature failure. Fuser type = 2 923.50 Fuser over temperature failure. Fuser type = 1 2-100 Service Manual Description/Action Possible repair actions The fuser hot roll has exceeded the proper operating temperature. 1.
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4062 Error code or message 923.51 Error contents Fuser over temperature failure. Fuser type = 1 923.75 Fuser over temperature failure. Fuser type = 2 923.76 Fuser over temperature failure. Fuser type = 2 924.00 Open fuser thermistor check Description/Action The fuser hot roll has exceeded the proper operating temperature. Replace the fuser unit assembly if problem remains. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23.
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4062 Error code or message 924.76 Error contents Description/Action Open fuser thermistor check failure. The fuser thermistor has failed. Fuser type = 2 Fuser page count has exceeded life. 925.00 Incorrect fuser or fuser lamp detected. Fuser type = 1 925.01 Incorrect fuser or fuser lamp detected. Fuser type = 1 925.02 Incorrect fuser or fuser lamp detected. Fuser type = 1 925.25 Incorrect fuser or fuser lamp detected.
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4062 Error code or message 925.26 Error contents Incorrect fuser or fuser lamp detected. Fuser type = 2 925.27 Incorrect fuser or fuser lamp detected. Fuser type = 2 925.50 Incorrect fuser or fuser lamp detected. Fuser type = 1 Description/Action Possible repair actions The machine detected a 115 V lamp in a 220 V machine. The fuser lamp has an excessive wattage rating. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2.
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4062 Error code or message 925.52 Error contents Incorrect fuser or fuser lamp detected. Fuser type = 1 Description/Action Possible repair actions The machine detected a 115 V lamp in a 220 V machine. The fuser lamp has an excessive wattage rating. 1. Turn the machine off/on and ensure the fuser unit assembly is properly installed. 2. Ensure the proper voltage fuser is installed in the machine. 3. Replace the fuser unit assembly if problem remains.
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4062 Error code or message Error contents Description/Action Possible repair actions 927.01 Main cooling fan failure. The cooling fan is obstructed or has failed. 1. Check for cooling fan obstructions. 2. Check the connections on the main cooling fan. 3. Replace the main cooling fan. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 927.02 Print cartridge cooling fan failure. The cooling fan is obstructed or has failed. 1. Check for cooling fan obstructions. 2.
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4062 Error code or message Error contents Description/Action Possible repair actions 927.07 Main cooling fan over speed failure. The main cooling fan does not reach the specified speed. 1. Check for cooling fan obstructions. 2. Check the connections on the main cooling fan. 3. Replace the main cooling fan. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 927.11 Print cartridge cooling fan failure The print cartridge cooling fan is obstructed or has failed. 1.
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4062 Error code or message Error contents Description/Action Possible repair actions 927.17 Print cartridge cooling fan over speed failure. The Print cartridge cooling fan does not reach the specified speed. 1. Check for cooling fan obstructions. 2. Check the connections on the main cooling fan. 3. Replace the print cartridge cooling fan. Go to “Print cartridge cooling fan removal (T650, T652, T654)” on page 4-57. 929.01 Sensor (toner empty) sensor failure.
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4062 Error code or message Error contents Description/Action Possible repair actions 933.00 Polygon mirror motor locked. No first laser H sync received. The hsync signal is missing or not at the correct voltage. Replace the printhead assembly. Go to “Printhead assembly removal (T650)” on page 4-60 or “Printhead assembly removal (T652, T654)” on page 4-61. 934.00 Mirror motor lost lock.
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4062 Error code or message 936.20 Error contents Main drive motor assembly failure Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4. Replace the system card assembly if problem remains.
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4062 Error code or message 936.31 Error contents Main drive motor assembly failure Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4. Replace the system card assembly if problem remains.
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4062 Error code or message 936.90 Error contents Main drive motor assembly failure Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4. Replace the system card assembly if problem remains.
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4062 Error code or message 937.41 Error contents Main drive motor assembly failure Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4. Replace the system card assembly if problem remains.
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4062 Error code or message 937.70 Error contents Main drive motor assembly failure Loss of lock detected by higher-level code. Motor = type 0 Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4.
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4062 Error code or message 937.71 Error contents Description/Action Possible repair actions Main drive motor assembly failure The main drive motor assembly may be faulty or has failed. Loss of lock detected by higher-level code. The internal duplex assembly is not properly grounded to the LVPS. This only applies to machines with an installed internal duplex assembly.
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4062 Error code or message 937.80 Error contents Main drive motor assembly failure Description/Action Possible repair actions The main drive motor assembly may be faulty or has failed. 1. Check all connections on the system card assembly. 2. Check all connections on the main drive motor assembly. 3. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 4. Replace the system card assembly if problem remains.
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4062 Error code or message 949.00 Error contents System card failure Description/Action Delay line calibration failure. Possible repair actions Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 950.xx NVRAM mismatch failure Mismatch between system card EEPROM and operator panel mirror. ".
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4062 Error code or message 954.xx Error contents NVRAM failure Description/Action NVRAM chip failure with system card assembly. Possible repair actions Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 955.xx 956.xx NVRAM failure System card processor failure The Code ROM or NAND flash failed the Cyclic Redundancy Check (CRC) check or the NAND experienced an uncorrectible multi-bit failure. Replace the system card assembly.
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4062 Error code or message 964.xx Error contents Emulation failure Description/Action Possible repair actions The download Emulation Cyclic Redundancy Check (CRC) detected a failure. 1. Disable the Download Emulation. Program the download emulation into the firmware card again. 1. 2. Replace the system card assembly if problem remains. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 975.
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4062 Error code or message 982.01 982.02 982.03 982.04 Error contents Communication failure Communication failure Communication failure Output option communication failure. Description/Action Possible repair actions Paper port communication device detected a validation failure. Replace the system card assembly. Paper port communication device detected a framing error or the receive buffer overflowed. Replace the system card assembly.
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4062 Error code or message 983.00 Error contents Communication failure Description/Action Invalid command received by the paper port device. Possible repair actions Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 984.00 Communication failure Invalid command parameter received by the paper port device. Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 985.
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4062 Error code or message Error contents Description/Action Possible repair actions 985.03 Service engine RFID communications Radio having problems communicating with printer 1. Check the RFID firmware card, RFID interface card, RFID cable, and RFID option for correct installation. Go to “High capacity input tray (HCIT) pick arm bracket assembly removal” on page 4-130. 2. Replace the RFID UHF option.
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4062 Error code or message Error contents Description/Action Possible repair actions 985.05 Service engine RFID communications Internal radio problem 1. Check the RFID firmware card, RFID interface card, RFID cable, and RFID option for correct installation. Go to “High capacity input tray (HCIT) pick arm bracket assembly removal” on page 4-130. 2. Replace the RFID UHF option. Note: There can be no other connectivity options installed on printers that have the RFID UHF option installed.
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4062 Error code or message Error contents Description/Action Possible repair actions 985.07 Service engine RFID communications Antenna is disconnected 1. Check the RFID firmware card, RFID interface card, RFID cable, and RFID option for correct installation. Go to “High capacity input tray (HCIT) pick arm bracket assembly removal” on page 4-130. 2. Replace the RFID UHF option. Note: There can be no other connectivity options installed on printers that have the RFID UHF option installed.
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4062 Error code or message 990.10 Error contents Paperport failure Description/Action Paperport overrun error Possible repair actions Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 990.11 Paperport failure Paperport parity error Replace the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 990.12 Paperport failure Paper port other paper port error Replace the system card assembly.
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4062 Error code or message 990.54 Error contents HCIT tray lift motor lost encoder failure Description/Action The HCIT tray lift motor is not reporting pulses back to the engine. Possible repair actions 1. Check for obstruction in the HCIT tray lift area. 2. Check the connections on the HCIT tray lift motor assembly for proper connection. 3. Replace the HCIT tray lift drive motor assembly if problem remains.
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4062 Service checks Sensor (input) service check Step 1 Check Check the sensor (input) for damage. Yes Go to step 2. Is the above component free from damage? No Replace the sensor (input). Go to “Sensor (input) removal (T650, T652, T654)” on page 4-71. 2 1. Enter the diagnostic mode 2. Select Base sensor test The sensor is working properly Go to step 2. Replace the Sensor (input). Replace the connection. 4.
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4062 Sensor (narrow media) service check Step 1 Check Check the sensor (narrow media) for damage. Yes Go to step 2. Is the above component free from damage? No Replace the fuser unit assembly. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. 2 1. Enter the diagnostic mode 2. Select Base sensor test The sensor is working properly Go to step 2. Replace fuser unit assembly. Replace the connection. 4.
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4062 Step 3 Check Check the above sensor for proper connection. Is the above sensor connected properly? Yes Replace the duplex input sensor assembly (internal duplex only). No Replace the connection. Go to “Duplex input sensor assembly removal (T652, T654)” on page 4-20 or replace the external duplex unit assembly (external duplex only). Sensor (duplex input) service check (external duplex only) Step 1 Check Check the sensor (duplex input) for damage. Yes Go to step 2.
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4062 Sensor (pass through) service check Step 1 Check Yes 1. Enter the diagnostic mode 2. Select Input tray tests No The sensor is working properly Go to step 2. Replace the sensor (pass through). Replace the connection. 3. Select Sensor test 4. Select the appropriate tray number 5. Observe the line item “pass through” for the appropriate media tray Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
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4062 Step 1 Check Check the media size setup and tray guides for all media trays. Yes Go to step 2. Replace the media, or change the media size setup. Remove any excess new media. Go to step 3 Replace the damaged media with new. Go to step 4. Go to step 5. Remove obstructions. Go to step 6. Go to step 8. Go to step 7. Clean or replace the MPF pick roll assembly. Does the media size, in use, match the size set for all media trays? 2 Check the media trays for overfilling.
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4062 Step 12 Check Perform a print test and check the duplex drive motor assembly for proper operation. Yes Go to step 17. Does the above component operate properly? No Replace the duplex drive motor assembly. Go to “Duplex drive motor assembly removal (T652, T654)” on page 4-19. 13 Check media origination. Go to step 14. Go to step 16. Go to step 15. Replace the external duplex assembly. Go to step 17. Replace the external duplex assembly. Go to step 17.
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4062 Step 20 Check Yes Perform a print test and check the pick arm assembly. Go to step 21. Replace the pick arm assembly. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. Go to step 22. Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. Contact next highest level of tech support. Problem solved.
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4062 Step 5 Check Yes Check the above sensor for proper connection. Is the above sensor connected properly? Replace the sensor (input). No Replace the connection. Go to “Sensor (input) removal (T650, T652, T654)” on page 4-71. 6 Check the sensor (fuser output) for proper operation. Go to step 8. Go to step 7. Replace the fuser unit assembly. Replace the connection. 1. Enter the diagnostic mode 2. Select Base sensor test 3.
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4062 Step 2 Check Check the MPF pick roll assembly. Yes Go to step 3. Is the above component free of excess wear and contamination? No Clean or replace the MPF pick roll assembly. Go to “MPF pick roll assembly removal (T650, T652, T654)” on page 4-38. 3 Perform a MPF print test and check the MPF pick solenoid for proper operation. Go to step 4. Go to “MPF pick solenoid assembly removal (T650, T652, T654)” on page 4-39.
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4062 Sensor (input) static jam service check Use this procedure for the following jams: • 200.13 Step 1 Check Yes Check the media path for partially fed or jammed media. Go to step 2. Remove any prestaged or jammed media. Go to step 4. Go to step 3. Replace the Sensor (input). Replace the connection. Is the media path free from partially fed or jammed media? 2 Check the sensor (input) for proper operation. No 1. Enter the diagnostic mode 2. Select Base sensor test 3.
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4062 Step 5 Check Check the sensor (fuser output) for proper operation. Yes No Go to step 7. Go to step 6. Replace the fuser unit assembly. Replace the connection. 1. Enter the diagnostic mode 2. Select Base sensor tests 3. Observe the line item “output” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked. 6 Check the above sensor for proper connection.
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4062 Sensor (fuser output) lingering jam service check. Use this procedure for the following jams: • 202.01 • 202.02 • 202.07 • 202.10 • 202.11 • 202.12 • 202.26 • 202.27 • 202.32 • 202.34 • 202.35 • 202.36 • 202.37 • 202.51 • 202.52 • 202.57 • 202.59 • 202.60 • 202.61 • 202.62 • 202.76 • 202.77 • 202.82 • 202.84 • 202.85 • 202.86 • 202.87 Step 1 Check Check the media size setup and tray guides for all media trays. Yes Go to step 2.
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4062 Step 8 Check Yes Perform a print test and check the redrive motor assembly for proper operation. Go to step 9. Does the above component operate properly? No Replace the redrive motor assembly. Go to “Redrive assembly removal (T650, T652, T654)” on page 4-62. 9 Perform a print test. Contact next highest level of tech support. Does the problem remain? Problem solved. Sensor (fuser output) static jam service check Use this procedure for the following jams: • 202.06 • 202.13 • 202.
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4062 Sensor (narrow media) late jam service check. Use this procedure for the following jams: • 201.04 • 201.06 • 201.29 • 201.56 • 201.79 • 201.81 Step 1 Check Check the media size setup and tray guides for all media trays. • 201.31 • 201.54 Yes Go to step 2. Replace the media, or change the media size setup. Go to step 3. Remove and properly re-install the media. Check the fuser unit assembly for damage and life expiration. Replace the fuser unit assembly. Go to step 4.
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4062 Step 9 Check Yes Perform a print test and check the main motor assembly. Go to step 10. Is the media properly transported and able to reach the sensor (fuser output)? No Replace the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 10 Perform a print test. Contact next highest level of tech support. Does the problem remain? Problem solved. Sensor (narrow media) static jam service check Use this procedure for the following jams: • 202.
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4062 Sensor (duplex input) late jam service check. Use this procedure for the following jams: • 230.02 • 231.00 Step 1 Check Check the door assembly, rear. Yes Go to step 2. Open then properly close the door assembly, rear. Go to step 3. Open then properly close the fuser access door. Go to step 4 Go to step 10 Go to step 5 Remove obstructions. Go to step 6 Replace the redrive assembly. Is the above component properly closed? 2 Check the fuser access door.
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4062 Step 9 Check Yes Check the above sensor for proper connection. Is the above sensor connected properly? Replace the Sensor (duplex input). No Replace the connection. Go to “Sensor (duplex input) removal (T652, T654)” on page 4-68. 10 Perform a print test and check the duplex drive motor assembly for proper operation. Go to step 14. Does the above component operate properly? Replace the duplex drive motor assembly. Go to “Duplex drive motor assembly removal (T652, T654)” on page 4-19.
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4062 Step 3 Check Check the duplex guide assembly, front for damage. Yes Go to step 4. Is the above component free from damage? No Replace the duplex guide assembly, front. Go to “Duplex guide assembly, front removal (T652, T654)” on page 4-21. 4 Check the sensor (duplex input) for proper operation. Go to step 6. Go to step 5. Replace the sensor (duplex input). Replace the connection. 1. Enter the diagnostic mode 2. Select Duplex tests 3. Select sensor test 4.
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4062 Sensor (duplex input) static jam service check. Use this procedure for the following jams: • 230.13 • 238.01 Step 1 • 238.03 Check Check media origination. • 238.05 • 238.07 Yes No Go to step 2 Go to step 5 Go to step 3. Remove any prestaged or jammed media. Go to step 7. Go to step 4. Replace the sensor (duplex input). Replace the connection. Did the media originate from the internal duplex? 2 Check the media path for partially fed or jammed media.
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4062 Sensor (pass through) late jam service check Use this procedure for the following jams: • 242.02 • 242.03 • 242.04 • 242.05 • 242.06 • 242.10 • 242.16 • 242.37 • 243.02 • 243.03 • 243.04 • 243.04 • 243.05 • 243.06 • 243.10 • 243.16 • 243.37 • 244.02 • 244.03 • 244.04 • 244.05 • 244.06 • 244.10 • 244.16 • 244.37 • 245.02 • 245.03 • 245.04 • 245.05 • 245.06 • 245.10 • 245.13 • 245.16 • 245.37 Step 1 Check Check the media size setup and tray guides for all media trays.
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4062 Step 7 Check Yes Check the above sensor for proper connection. Is the above sensor connected properly? Replace the appropriate Sensor (pass through). No Replace the connection. Go to “250-sheet controller card assembly removal” on page 4-106. 8 Perform a print test and check the pick arm assembly for the appropriate media tray. Go to step 8. Is the media properly picked and advanced out of the appropriate media tray? 9 Perform a print test and check the main motor assembly.
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4062 Step Check Yes 3 Check the appropriate media tray sensor (pass through) for proper operation. No Go to step 5. Go to step 4. Replace the appropriate Sensor (pass through). Replace the connection. 1. Enter the diagnostic mode 2. Select Input tray tests 3. Sensor test 4. Select the appropriate tray number 3.
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4062 Step Check 2 Check the appropriate media tray sensor (pass through) for proper operation. Yes No Go to step 5. Go to step 4. Replace the appropriate sensor (pass through). Replace the connection. 1. Enter the diagnostic mode 2. Select Input tray tests 3. Sensor test 4. Select the appropriate tray number 3.
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4062 Step 5 Check Perform a print test using the output option. Does the error continue? Yes Replace the output option. No Problem solved. Sensor (stapler pass through) lingering jam service check Step 1 Check Check the output option for proper installation. Yes Go to step 2. Remove then reinstall the output option Go to step 3. Remove obstructions. Go to step 5. Go to step 4. Replace the stapler unit assembly. Replace the connection.
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4062 Step 2 Check Check the sensor (stapler pass through) for proper operation. Yes No Go to step 4. Go to step 3. Replace the stapler unit assembly. Replace the connection. 1. Enter the diagnostic mode 2. Select Finisher sensor test 3. Select Sensor test 4. Select pass & media 5. Observe the line item “passthru” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked. 3 Check the above sensor for proper connection.
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4062 Step 4 Check Check the above sensor for proper connection. Is the above sensor connected properly? Yes Replace the sensor (output pass through). No Replace the connection. Go to “High capacity stacker sensor (pass through) removal” on page 4-144. Go to “5-bin mailbox sensor (pass through) removal” on page 4-90. Go to “Output expander sensor (pass through) removal” on page 4-169. 5 Perform a print test using the output option. Does the error continue? Replace the output option. Problem solved.
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4062 Step 4 Check Check the above sensor for proper connection. Is the above sensor connected properly? Yes Replace the sensor (output pass through). No Replace the connection. Go to “High capacity stacker sensor (pass through) removal” on page 4-144. Go to “5-bin mailbox sensor (pass through) removal” on page 4-90. Go to “Output expander sensor (pass through) removal” on page 4-169. 5 Perform a print test using the output option. Does the error continue? Replace the output option. Problem solved.
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4062 Step 3 Check Check the above sensor for proper connection. Is the above sensor connected properly? Yes Replace the sensor (output pass through). No Replace the connection. Go to “High capacity stacker sensor (pass through) removal” on page 4-144. Go to “5-bin mailbox sensor (pass through) removal” on page 4-90. Go to “Output expander sensor (pass through) removal” on page 4-169. 4 Perform a print test using the output option. Does the error continue? Replace the output option. Problem solved.
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4062 Sensor (mailbox empty) lingering jam service check Step 1 Check Check the output option for proper installation. Yes Go to step 2. Remove then reinstall the output option Go to step 3. Remove obstructions. Go to step 5. Go to step 4. Replace the sensor (mailbox empty). Replace the connection. Is the above component properly installed? 2 Check for obstructions in the media path between the Sensor (mailbox empty) machine and the media bin.
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4062 Step 3 Check Check the above sensor for proper connection. Is the above sensor connected properly? Yes Replace the sensor (mailbox empty). No Replace the connection. Go to “5-bin mailbox sensor (media bin empty) removal” on page 4-91. 4 Perform a print test using the output option. Does the error continue? Replace the output option. Problem solved. Sensor (toner empty) service check Step 1 Check Check the sensor (toner empty) for proper installation. Yes go to step 2.
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4062 2 Check the system card assembly. Go to step 4. Contact next level of support. Go to step 5. Problem solved. Go to step 6. Problem solved. Contact the next level of support. Problem solved. Contact the next level of support. Problem solved. Was the system card assembly recently replaced? 3 Replace the current operator panel assembly with the original operator panel assembly. Does the error remain? 4 Replace the current system card assembly with the original system card assembly.
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4062 Image quality trouble Printer Related Troubleshooting Note: First, get a printout as a base, and follow the symptom table to identify the possible failing FRU’s. Image quality symptoms • • • • • • • • • • • • • • Faint print (low contrast)– “Faint print (Low contrast)” on page 2-158. Blank print (no print)– “Blank print (no print)” on page 2-160. Solid black– “Solid black” on page 2-162.
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4062 Image Quality Faint print (Low contrast) Leading edge Trailing edge Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step 1 Check Check the media condition. Yes No Problem solved. Go to step 2. Go to step 3. Replace the print cartridge. Go to step 4. Replace the transfer roll assembly. Load new, dry, recommended media, and perform a print test. Is the image density normal? 2 Check the toner level.
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4062 Step 7 Check Check the printhead assembly for proper connection. Is the above component properly connected? Yes Replace the printhead assembly. No Replace the connections. Go to “Printhead assembly removal (T650)” on page 4-60 or “Printhead assembly removal (T652, T654)” on page 4-61. 8 Perform a print test. Does the problem remain? Contact next highest level of tech support. Problem solved.
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4062 Blank print (no print) Check the media path for foreign objects such as staples, clips, scraps of media. Step 1 Check Check the media condition. Yes No Problem solved. Go to step 2. Go to step 3. Replace the print cartridge. Go to step 4. Reinstall the transfer roll assembly. Go to step 5. Replace the left and or right transfer roll brackets. Load new, dry, recommended media, and perform a print test. Is the image density normal? 2 Check the toner level.
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4062 Step 7 Check Check the laser beam route. Yes Go to step 8. Remove debris or clean the printhead assembly window. Replace the HVPS card assembly. Replace the connections. Check for debris between the printhead assembly and the PC drum. Is the laser beam route free of debris and the glass window, in the printhead assembly, free of contamination? 8 Check the HVPS card assembly for proper connection.
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4062 Solid black Check the media path for foreign objects such as staples, clips, scraps of media. Step 1 Check Check the charge roll assembly for proper installation. Yes Go to step 2. Replace the charge roll assembly. Go to step 3. Inspect, clean and reinstall replace the print cartridge. Replace the HVPS card assembly. Replace the connection. Is the above component properly installed? 2 Check the print cartridge for proper installation.
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4062 Vertical lines and bands (process direction) Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? 2 Is the media transfer route and the media path clear of debris? Go to step 3. Remove debris or contamination. 3 Check the laser beam route. Go to step 4. Remove debris or clean the printhead assembly window. Go to step 5.
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4062 Step 7 Check Perform a print test. Yes Contact next highest level of tech support. Does the problem remain? No Problem solved. Horizontal white stripes or bands (side to side direction) Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? 2 Are the media transfer route and the media path free of contamination and debris? Go to step 3.
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4062 Step 6 Check Perform a print test. Does the problem remain? Yes Contact next highest level of tech support. No Problem solved. Vertical stripes (process direction) Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? 2 Are the media transfer route and the media path free of contamination or debris? Go to step 3. Remove debris or contamination.
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4062 Step 6 Check Yes Check the heat roll and pressure roll. Remove the fuser unit assembly. CAUTION: : Allow the fuser unit assembly to cool down. Replace the fuser unit assembly. No Go to step 7. Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. Is there contamination or cracks on the heat roll and/or pressure roll? 7 Perform a print test. Does the problem remain? Contact next highest level of tech support. Problem solved.
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4062 Step 4 Check Yes Check the charge roll assembly for contamination and wear. Go to step 5. Is the above component free of excess wear and contamination? 5 Check the transfer roll assembly for contamination and wear. Check the heat roll and pressure roll. Remove the fuser unit assembly. CAUTION: : Allow the fuser unit assembly to cool down. Replace the charge roll assembly. Go to “Access door removal (T650, T652, T654)” on page 4-8. Go to step 6.
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4062 Partial lack Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Go to step 3. Replace the print cartridge. Go to step 4. Remove debris or clean the printhead assembly window. Go to step 5. Replace the transfer roll assembly. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? 2 Check the toner level. Is the toner level normal? 3 Check the laser beam route.
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4062 Step 6 Check Perform a print test. Does the problem remain? Yes Contact next highest level of tech support. No Problem solved. Spots Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Go to step 3. Remove debris or contamination. Go to step 4. Replace the print cartridge. Go to step 5. Replace the charge roll assembly. Load new, dry, recommended media. Re-print the defective image.
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4062 Step 6 Check Yes Check the heat roll and pressure roll. Remove the fuser unit assembly. CAUTION: : Allow the fuser unit assembly to cool down. Replace the fuser unit assembly. No Go to step 7 Go to “Fuser unit assembly removal (T650, T652, T654)” on page 4-23. Is there contamination or cracks on the heat roll and/or pressure roll? 7 Check the printhead installation. Go to step 8. Is the above component properly installed? Reinstall and adjust the printhead assembly.
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4062 After image Leading edge Trailing edge The ghost appears on the media which, may be the image from the previous page or part of the page currently printing. Step 1 Check Yes Check the media condition. No Go to step 2. Problem solved. Replace the fuser unit assembly. Go to step 4. Load new, dry, recommended media. Re-print the defective image. Does the error continue? 2 Check the heat roll and pressure roll. Remove the fuser unit assembly.
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4062 Background (fog) Leading edge Trailing edge Step 1 Check Check the media condition. Yes No Go to step 2. Problem solved. Go to step 3. Remove debris or contamination. Go to step 4. Inspect, clean and reinstall replace the print cartridge. Go to step 5. Replace the transfer roll assembly. Load new, dry, recommended media. Re-print the defective image. Does the error continue? 2 Check the media transfer route. Is the media path free of contamination or debris.
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4062 Step 7 Check Perform a print test. Does the problem remain? Yes No Contact next highest level of tech support. Problem solved. Yes No Skew Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step 1 Check Check printer installation placement. Go to step 2. Correct the installation placement. Go to step 3. Problem solved. Go to step 4. Remove obstructions. Go to step 5. Replace the transfer roll assembly.
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4062 Step 5 Check Check the aligner assembly for proper adjustment. Yes Go to step 6. Go to “Alignment assembly adjustment” on page 4-4. Perform a print test. Does the problem remain? Replace the aligner assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. Does the problem remain? 6 No Contact next highest level of tech support. Problem solved. Media damage Leading edge Trailing edge Step 1 Check Check printer installation placement. Yes No Go to step 2.
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4062 Step Check Yes 4 Check the transfer roll assembly for contamination and wear. Go to step 5. Is the above component free of excess wear and contamination? 5 Check the aligner assembly for proper adjustment. Go to step 6. Remove the fuser unit assembly. CAUTION: : Allow the fuser unit assembly to cool down. Replace the aligner assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. Does the problem remain? Check the heat roll and pressure roll.
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4062 No fuse Leading edge Trailing edge Step 1 Check Yes Check the fuser unit assembly installation. Go to step 2. Reinstall the fuser unit assembly. Go to step 3. Problem solved. Replace the fuser unit assembly. Go to step 4. Is the fuser unit assembly properly installed? 2 Check the media condition. No Load new, dry, recommended media. Re-print the defective image. Does the problem remain? 3 Check the heat roll and pressure roll. Remove the fuser unit assembly.
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4062 Step 5 Check Yes Perform a print test. No Replace the system card assembly. Does the problem remain? Problem solved. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. Network service check Note: Before starting this service check, print out the network setup page. This page is found under Menu Reports - Network Settings.
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4062 Step 10 Questions / actions Have the network administrator verify that the printer and PC’s IP address have identical subnet addresses. Yes No Go to step 12. Go to step 11. Problem resolved. Go to step 12. Are the subnet addresses the same? 11 Using the subnet address supplied by the network administrator, assign a unique IP address to the printer. Note: The printer IP address should match the IP address on the printer driver.
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4062-XXX 3. Diagnostic aids This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Understanding the printer control panel (models T650, T652, and T654) 1 9 Item 1 2 8 76 2 3 4 5 Description Display Navigation buttons Shows messages and pictures that communicate the status of the printer. Press the up or down arrow buttons to scroll through menus or menu items, or to increase or decrease a value when entering numbers.
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4062-XXX Item 8 Description Menu Opens the menu index Note: The menus are available only when the printer is in the Ready state. 9 USB Insert a flash drive into the front of the printer to print saved files. Note: Only the front USB port supports flash drives. Accessing service menus (models T650, T652, and T654) There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Mode 1. Turn off the printer. 2.
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4062-XXX Diagnostics mode (models T650, T652, and T654) Entering Diagnostics mode (models T650, T652, and T654) 1. Turn the printer off. 1. Press and hold and . 2. Turn the printer on. 3. Release the buttons after 10 seconds.
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4062-XXX DUPLEX TESTS (if installed) Quick Test See “Quick Test (duplex)” on page 3-12 Top Margin See “Top Margin (duplex)” on page 3-13 Sensor Test See “Sensor Test (duplex)” on page 3-13 Motor Test See “Motor Test (duplex)” on page 3-14 Duplex Feed 1 See “Duplex Feed 1” on page 3-14 Duplex Feed 2 See “Duplex Feed 2” on page 3-14 INPUT TRAY TESTS Feed Tests See “Feed Tests (input tray)” on page 3-15 Sensor Test See “Sensor Test (input tray)” on page 3-15 OUTPUT BIN TESTS Feed Tests See “F
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4062-XXX EP SETUP EP Defaults See “EP Defaults” on page 3-21 Fuser Temp See “Fuser Temperature (Fuser Temp)” on page 3-21 Fuser Page Count See “Fuser Page Count” on page 3-21 Warm Up Time See “Warm Up Time” on page 3-21 Transfer See “Transfer” on page 3-21 Print Contrast See “Print Contrast” on page 3-22 Charge Roll See “Charge Roll” on page 3-22 Gap Adjust See “Gap Adjust” on page 3-22 EVENT LOG Display Log See “Display Log” on page 3-23 Print Log See “Print Log” on page 3-23 Clear Log
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4062-XXX The print registration range is: Variable Description Value Direction of change T= Top margin -25 to +25 Each increment causes approximately 4 pels shift (at 600 dpi). A positive change moves the image down the page and increases the top margin. A negative change moves the image up and decreases the top margin. B= Bottom margin -20 to +20 Each increment causes approximately 0.55 mm shift in the bottom margin.
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4062-XXX PRINT TESTS Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options. The contents of the Print Test Page varies depending on the media installed in the selected input source. Check each Test Page from each source to assist in print quality and paper feed problems. To run the Print Test Page: 1. Select PRINT TESTS from the Diagnostics menu. 2. Select the media source.
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4062-XXX NVRAM. The CONFIG MENU print quality test pages are identical to the DIAGNOSTIC print quality test pages with the exception of the first page. The first print quality test page from the CONFIG MENU does not include EP or Printer setup.
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4062-XXX USB HS Test Mode 1. Select USB HS Test Mode from HARDWARE TESTS. 2. Press until the appears next to the Port to be tested, and then press 3. Select the desired Test, and then press . . Port Test Appears on the display Port 0 Test J Test K Test SEO NAK Test Packet Test Force Enabled USB High Speed Certification Testing... Port 1 Test J Test K Test SEO NAK Test Packet Test Force Enabled USB High Speed Certification Testing...
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4062-XXX RFID Option Test This test confirms that the RFID firmware and hardware are working properly. In the event that the test fails, it is recommended that the test be repeated to confirm that the problem is not intermittent or caused by a single failed piece of RFID media. Note: If the printer has problems picking RFID media from a tray, try using a shorter stack of media (< 100 sheets) before assuming a pick mechanism problem. To run the RFID Option Test, select RFID Option Test from the menu. 1.
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4062-XXX 2. Reload RFID media in Tray 2 with the RFID media that was just printed in step 1, and then press continue. The test page will be printed. Note: The sheet should be placed face down with the arrow pointing toward the front of the printer. If the page looks like this: If the page looks like this: T65x RFID Option Test Step 1. T65x RFID Option Test Step 1. Step 1 is complete. Step 1 is complete. 1. Place this sheet in Tray 2 face-down with t arrow pointing toward the front of the printe 2.
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4062-XXX 3. Load plain media in Tray 2, and then press Continue. The test page will be printed. If the page looks like this: T65x RFID Option Test Step 3. Step three is complete. If this image appears at the bottom of this sheet, the test is a SUCCESS. Then step 3 of the test passed and the RFID Option Test is complete. The RFID firmware and hardware are working properly. If the page looks like this: T65x RFID Option Test Step 3. Step three is complete.
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4062-XXX duplexed pages (Continuous) until Stop “Top Margin (duplex)” on page 3-13. is pressed. For information about changing the margin, see Note: Before you set the duplex top margin, be sure to set the registration. See “REGISTRATION” on page 3-5. The paper you choose to print the page on should be either Letter or A4. To run the Quick Test (duplex): 1. Select Quick Test from DUPLEX TESTS. 2. Select Single or Continuous. • The single Duplex Quick test cannot be canceled.
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4062-XXX • Duplex input sensor • Duplex exit sensor 3. Press Back or Stop to exit the test. Motor Test (duplex) This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power (PWM) required for each speed and calculating the KE value. To run the Motor Test (duplex): 1. Select Motor Test from DUPLEX TESTS.
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4062-XXX Feed Tests (input tray) This test lets 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 turns off during this test. The only way to observe the paper path is to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in the output bin. To run the Input Tray Feed Tests: 1. Select Feed Tests from INPUT TRAY TESTS. 2.
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4062-XXX Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test. These tests can use any media size or envelope supported by the printer.
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4062-XXX To run the Sensor Test for the standard bin: 1. Select Sensor Test from OUTPUT BIN TESTS. 2. Select Standard Bin from Sensor Tests. 3. Standard Bin Testing displays briefly, and then Bin Empty empty displays. 4. Select NearFull or Full sensor to test. The following screen is displayed: Standard Bin x Full=Open NearFull=Open Bin Empty empty • Full–Bin full sensor • NearFull–Bin near full sensor 5. Manually actuate the bin sensor by moving the flag in and out of the sensor.
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4062-XXX Sensor Tests (5-bin mailbox) 1. Select Sensor Tests from OUTPUT BIN TESTS. 2. Select Output Bin x (x=number of the output option to be tested). The following screen is displayed: Output Bin x P1=OP P2=OP L=NL • passThru–5-bin mailbox pass thru sensor shows Open or Closed • mailboxEmpty–5-bin mailbox empty sensor shows Normal for a normal level, NearFull for nearly full, and Full for full. 3. Manually actuate each of the sensors of the 5-bin mailbox,.
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4062-XXX To run the Finisher Sensor Test: 1. Select Sensor Test from FINISHER TESTS. 2. Select one of the four tests to perform:. Each of the tests displays the individual sensors that can be manually actuated, and the display shows Open or Closed.
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4062-XXX The page count can only be viewed and cannot be changed. To view the page count: 1. Select Page Count from PRINTER SETUP. 2. Press Back to return to PRINTER SETUP. Perm Page Count (permanent page count) The permanent page count can only be viewed and cannot be changed. To view the permanent page count: 1. Select Perm Page Count from PRINTER SETUP. 2. Press Back to return to PRINTER SETUP. Serial Number The serial number can only be viewed and cannot be changed. To view the serial number: 1.
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4062-XXX • To change a digit or character, press • When the last digit is changed, press to increase or to decrease the value. to validate the Configuration ID 1. If Invalid ID appears, the entry is discarded, and the previous Configuration ID 1 is displayed on the screen. If the process is successful, Submitting Selection appears on the display, followed by the current value for Confirguration ID 2. 4. Repeat the steps for entering the Configuration ID, and press .
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4062-XXX Print Contrast The print contrast setting controls the developer voltage offset. The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium. Charge Roll The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium. Gap Adjust The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems.
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4062-XXX REPORTS Prints a Menu Settings Page. To print the Menu Settings Page: 1. Select Menu Settings Page from REPORTS. 2. Press Back to return to DIAGNOSTICS. EVENT LOG Display Log The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors have occurred). If an error occurs after the log is full, the oldest error is discarded.
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4062-XXX • Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Select Print Log from EVENT LOG. Press Back to return to EVENT LOG. Clear Log Use Clear Log to remove the current information in the Event Log. This affects both the viewed log and the printed log information. 1. Select Clear Log from the Event Log menu. 2.
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4062-XXX Configuration menu (CONFIG MENU) (models T650, T652, and T654) Entering Configuration Menu (models T650, T652, and T654) 1. Turn off the printer. 2. Press and hold and . 3. Turn on the printer. 4. Release the buttons after ten seconds. The message CONFIG MENU displays on the top line of the operator panel.
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4062-XXX To view the maintenance page count: 1. Select Maint Cnt Value from CONFIG MENU. 2. Press to view the value. Press Back to return to the main Configuration menu. Maintenance page counter reset (Reset Cnt) After scheduled maintenance, the servicer needs to reset the page counter. To reset the maintenance page count to zero: Select Reset Cnt from the Configuration menu, and then select Reset. When the reset operation is complete, the display returns to the Configuration menu.
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4062-XXX To print the Event Log, select Reports from CONFIG MENU, and then Event Log. The message Printing EVENT LOG is displayed. The event log provides a history of printer errors. The event log can only be printed in CONFIG MENU. SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing.
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4062-XXX Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base and Restore Network. Network does not appear unless you have a network printer. The following settings are not changed: • Display language • Settings in the NETWORK/PORTS MENU group. LES Applications This disables all installed Lexmark Embedded Solution applications. Settings are Disable and Enable. The default is Enable.
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4062-XXX Best Speed Settings are For short jobs and For long jobs. Make a setting change, and then press selection appears on the display. . Submitting Exit Config Menu (models T650, T652, and T654) Press to exit the CONFIG MENU. The message Resetting the Printer displays, and the printer performs a POR and restarts in normal mode. Understanding the printer control panel (model T656) Item 1 2 Description Display Keypad 1 4 GHI 7 3 View printing options as well as status and error messages.
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4062-XXX Item Description 4 Indicator light 5 Stop Indicates the printer status: • Off–The power is off. • Blinking green–The printer is warming up, processing data, or printing. • Solid green–The printer is on, but idle. • Blinking red–Operator intervention is needed. Stops all printer activity A list of options is offered once Stopped appears on the display. Accessing service menus (model T656) There are different test menus that can be accessed during POR to identify problems with the printer.
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4062-XXX Diagnostics Menu (model T656) Entering Diagnostics Menu (model T656) 1. 2. 3. 4. Turn off the printer. Press and hold 3 and 6 buttons simultaneously. Turn on the printer. Release the buttons after 10 seconds. Available tests The tests display on the operator panel in the order shown: Note: Some menus are not available, depending on the configuration of the printer.
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4062-XXX Diagnostics Menu tests (Continued) Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) Envelope Feeder MP Feeder Sensor Tests See “Sensor Test (input tray)” on page 3-41 Tray 1 Tray 2 (if installed) Tray 3 (if installed) Tray 4 (if installed) Tray 5 (if installed) Envelope Feeder MP Feeder OUTPUT BIN TESTS See “OUTPUT BIN TESTS” on page 3-41 Feed Tests Standard Bin Sensor Tests Standard Bin BASE SENSOR TEST See “BASE SENSOR TEST” on page 3-42 Toner
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4062-XXX Diagnostics Menu tests (Continued) Warm Up Time See “Warm Up Time” on page 3-46 Transfer See “Transfer” on page 3-46 Print Contrast See “Print Contrast” on page 3-46 Charge Roll See “Charge Roll” on page 3-46 Gap Adjust See “Gap Adjust” on page 3-47 Auto Dark Adjust See “Auto Dark Adjust” on page 3-47 REPORTS See “REPORTS” on page 3-47 See “Menu Settings Page” on page 3-47 Menu Settings Page EVENT LOG See “EVENT LOG” on page 3-47 See “Display Log” on page 3-47 Display Log Print Log
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4062-XXX Description Value Direction of change Left Margin -25 to +25 A positive change moves the image right, and a negative change moves the image left. No compression occurs. Right Margin -10 to +10 A positive change moves the image right, and a negative change moves the image left. To set print registration: 1. Print the Quick Test page. a. Touch REGISTRATION from the Diagnostics Menu. b. Touch to select Quick Test. You may need to scroll to the next page.
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4062-XXX The message Quick Test Printing… appears on the display. Once the Quick Test Page completes printing, the Registration screen displays again. 3. Touch Back to return to the Diagnostics Menu. PRINT TESTS Selections on the screen vary since only installed input sources are listed, followed by Printing Quality Test Pages. Input source tests The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the installed input options.
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4062-XXX • Contents of the EVENT LOG from DIAGNOSTICS. • Configuration information, including printer serial number, controller code level, engine code level, operator panel code level, font versions, and cartridge information. • Default values for the QUALITY MENU settings used to print the pages.
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4062-XXX DRAM Test The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes patterns of data to DRAM to verify that each bit in memory can be set and read correctly. To run the DRAM Test: 1. Touch to select DRAM Test from the menu. The message DRAM Test Testing… displays. Then the message Resetting Printer appears, and the power indicator light blinks red. 2. Turn the printer off and on. While the DRAM test executes, the power indicator blinks green.
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4062-XXX Port Test Appears on the display Single Step Get Device Descriptor USB High Speed Certification Testing... Single Step Set Feature USB High Speed Certification Testing... To stop testing before completion, turn the printer off. DUPLEX TESTS Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page.
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4062-XXX • An increase moves the top margin down and widens the top margin. A decrease moves the top margin upward and narrows the top margin. 4. Touch Submit. 5. Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary. Left Margin (duplex) To set the Left Margin (duplex): 1. Print the Quick Test (duplex): a. Touch to select Quick Test from DUPLEX TESTS. b. Select Single. c.
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4062-XXX 2. When the motor stops, the results are displayed. Listed below is an example of such results: Duplex Motor Test Test Passed Avg. PWM of High-Speed Test: 1d Avg. PWM of Low-Speed Test: Oe Max. PWM of Low-Speed Test: 00 Min. PWM of Low-Speed Test: 0b Motor KE Value: 2d Motor Test Results: 00 3. Touch Back or press Stop to exit the test. Duplex Feed 1 This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the supported paper sizes.
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4062-XXX Sensor Test (input tray) This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test: 1. Touch to select the Sensor Test from INPUT TRAY TESTS. 2. Touch to select the input source from the sources displayed on the Sensor Test menu. All installed sources are listed. 3. Select the sensor to test. Various sources have different combinations of sensors.
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4062-XXX To run the Sensor Test for the standard bin: 1. Touch to select Sensor Test from OUTPUT BIN TESTS. 2. Touch to select Standard Bin from Sensor Tests. 3. Manually actuate the bin sensor by moving the flag in and out of the sensor, and the display changes. The following screen is displayed: Bin Empty: empty or Bin Empty: full. 4. Press Stop to exit the test. BASE SENSOR TEST This test is used to determine if the sensors located inside the printer are working correctly.
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4062-XXX DEVICE TESTS Quick Disk Test This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the block is good, the saved data is written back to the disk. To run the Quick Disk Test: 1. Touch to select Quick Disk Test from DEVICE TESTS. The power indicator blinks while the test is in progress, and quick Disk Test Testing… displays.
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4062-XXX PRINTER SETUP PRINTER SETUP Defaults US Printed Page Count 127 Permanent Page Count 127 Serial Number xxxxxxx Engine Setting 1 0 Engine Setting 2 0 Submit Back The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective.
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4062-XXX Configuration ID The two configuration IDs are used to communicate information about certain areas of the printer that cannot be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer is manufactured, however, the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever you replace the system board. The IDs consist of eight hexadecimal characters, including 0 through 9 and A through F.
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4062-XXX The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to display these additional menus. Note: If you make changes, touch Submit to make the change effective. EP Defaults This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes this is used to help correct print quality problems. To restore EP Defaults: 1. Touch to select EP Defaults from EP SETUP. 2.
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4062-XXX Touch Back to return to Diagnostics Menu. Gap Adjust The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems. However, increasing this value also results in slower overall performance, measured in pages per minute. The range of values is 0 to 255, and the default value is 0. Touch Back to return to Diagnostics Menu. Auto Dark Adjust The settings are Enable and Disable.
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4062-XXX Print Log Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than Configuration Menu. The Event Log printed from Diagnostics Menu includes: • • • • Detailed printer information, including code versions Time and date stamps Page counts for most errors Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis.
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4062-XXX Configuration menu (CONFIG MENU) (model T656) Entering Configuration Menu (model T656) 1. 2. 3. 4. Turn off the printer. Press and hold 2 and 6 buttons simultaneously. Turn on the printer. Release the buttons after 10 seconds. Available menus Note: Some menus are not available, depending on the configuration of the printer.
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4062-XXX The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job containing a single page increments the counter by one and a duplex page by two. At 300,000, the customer is reminded that the printer requires scheduled maintenance. This counter is reset by the servicer after an 80 Scheduled Maintenance message displays and a maintenance kit is installed.
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4062-XXX Print Quality Pages The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu (CONFIG MENU). When printed from the Diagnostics Menu, additional information is included, and the print cartridge lockout is bypassed. See “Print quality pages (Prt Quality Pgs)” on page 3-26. Additional configuration information may be included on the print quality pages which is not included on the print menu page.
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4062-XXX 3. Touch Back to return to EVENT LOG. Note: An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors. However, the event log printed from DIAGNOSTICS mode does include this information. SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing.
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4062-XXX To change the PPDS Emulation setting: 1. Touch to select PPDS Emulation from the Configuration Menu. 2. The panel displays the setting's name in the header and [setting's current value] below the header row. Touch or to change the setting. The selections are Deactivate and Activate. The default is Deactivate. 3. Touch Submit to save your change. Touch Back to exit without changing the value.
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4062-XXX Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base, Restore STD NET, or Restore LES. Restore LES enables you to remove all Lexmark Embedded Solutions applications (LES). Network does not appear unless you have a network printer. The following settings are not changed: • Display language • Settings in the NETWORK/PORTS MENU group. To reset factory defaults: 1. Touch 2.
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4062-XXX Paper Prompts When a tray is out of the indicated paper size, a prompt is sent to the user to load paper in a tray. This setting controls the tray the user is directed to fill. 1. Touch to select Paper Prompts from the Configuration Menu. The panel displays the setting's name in the header and [setting's current value] row. 2. Touch or to change the value. The values are Auto (default), Multi-Purpose Feeder, and Manual Paper. 3. Touch Submit to save the change.
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4062-XXX Disk Encryption If a hard disk is installed, Disk Encryption selects whether the data on the disk is encrypted or not. The values are Disable and Enable. This setting determines if the printer encrypts the information that it writes to the hard disk. Warning: If the value is changed from Enable to Disable or from Disable to Enable, then the printer completely formats the hard disk. All information on the disk will be unrecoverable. To change this setting: 1.
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4062-XXX Wipe Disk This setting provides you with a tool for erasing the contents of a disk. Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered. To change this setting: 1. Touch to select Wipe Disk from Configuration Menu. Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD. 2.
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4062-XXX LES Applications This disables all installed Lexmark Embedded Solution applications. The default is Enable. To change this setting: 1. Touch to select LES Applications from the Configuration Menu. Note: If an advanced password has been established, you must enter this password in order to change the setting. If no advanced password exists, you can establish one by using the keyboard that appears on the LCD. 2. Touch Submit to save the change.
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4062-XXX USB speed To change this setting: 1. Touch to select USB speed from the Configuration Menu. 2. Touch or to change the value. The values are Auto (default) and Full. 3. Touch Submit to save the change. Touch Back to cancel and return to the Configuration Menu. Exit Configuration Menu (model T656) Touch Exit Config Menu to exit the Configuration Menu. The printer performs a POR, and the printer returns to the ready mode.
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4062-XXX Printer overview CAUTION: Do not set up this product or make any electrical or cabling connections, such as the power cord or options and features, during a lightning storm. Basic model The following illustration shows the basic printer model. 1 2 3 4 Feature 1 Standard exit bin 2 Printer control panel 3 Multipurpose feeder 4 Standard tray (Tray 1) 1Based on 75 g/m2 (20 lb.) paper.
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4062-XXX Printer theory Model T650 with duplex, paper path, rolls, and sensors Standard bin full actuator and sensor (standard bin full) Sensor (input) PC cartridge PC drum Diverter Sensor (fuser output) Sensor (narrow media) Sensor (duplex input) Sensor (option pass through) Sensor (duplex double feed) Sensor (duplex exit) Pick arm assembly Diagnostic aids 3-61
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4062-XXX Models T652 and T654 paper path rolls and sensors Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Diverter PC cartridge Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm assembly Functions of main components • • • • • • • • Media tray assembly Pic arm assembly (feed) MPF Xerographics Transfer Fuser Drive Electrical components and rolls Media tray assembly It is necessary to adjust the media tray rear gui
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4062-XXX The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear. The rear guide should come into contact with the media and hold it in position. Side guide The media tray assembly is designed so it can adapt to the media width in the media feed direction by moving the side guide to the left or right. Wear strips The wear strips are designed to provide a fixed resistance to ensure that a single piece of paper is properly fed out of the media tray.
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4062-XXX The media size set for the media tray assembly is transmitted to the switch (media size) by moving these guides. The media size is detected by the on/off information of these switches.
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4062-XXX Switch (media size) This switch (media size) sets the size of media supplied from each media tray assembly. A signal indicating the media size is transmitted as a voltage to the printer system card assembly. Sensor (media empty) If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area of the sensor (media empty). The sensor light is transmitted. When the sensing area is blocked (media is present), the signal is off.
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4062-XXX Supported paper sizes, types, and weights The following tables provide information on standard and optional paper sources and the types of paper they support. Note: For an unlisted paper size, select the closest larger listed size Paper sizes supported by the printer 250-or 550-sheet trays (standard or optional Paper size Dimensions A4 210 x 297 mm (8.3 x 11.7 in.) x A5 148 x 210 mm (5.8 x8.3in.) x A61,2 105 x 148 mm (4.1 x 5.8 in.) J15 B5 182 x 257 mm (7.2 x 10.1 in.
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4062-XXX Paper size Dimensions Other Envelope 98 x 162 mm (3.9 x 6.4 in.) to 176 x 250 mm (6.9 x 9.8 in.) 250-or 550-sheet trays (standard or optional Optional 2000-sheet tray Multipurpose feeder Duplex unit x 1 This size appears in the Paper Size menu only when the paper source does not support size sensing or when size sensing is turned off. 2 Only the standard exit bin supports this size. 3 This size setting formats the page for 216 x 356 mm (8.5 x 14 in.
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4062-XXX Transfer Transfer roll Transfer roll assembly The transfer roll assembly applies charge to the rear surface of the media when the media passes between the transfer roll assembly and photo conductor (drum). Thus, the toner image is transferred from the photo conductor (drum) surface to the media surface.
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4062-XXX Polygon printhead assembly The printhead scans the photo conductor drum surface with a laser beam. It consists of four components: laser diode (LD) card assembly, printhead motor, polygon mirror, and the start of scan card assembly. Polygon printhead 1. LD card assembly – generates the laser beam. The beam is turned on or off according to a print data signal coming from the system card. 2.
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4062-XXX Conceptual diagram of an image created by scanning Paper Path 600 dots/inch 600 scans/inch 3-70 Service Manual
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4062-XXX Oscillating printhead assembly The oscillating printhead scans the photo conductor drum surface with a laser beam. It consists of four components: laser diode (LD) card assembly, magnetic motor, mirror, and the start of scan card assembly. Oscillating printhead 1. LD card assembly – generates the laser beam. The beam is turned on or off according to a print data signal coming from the system card. 2.
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4062-XXX Fuser Fuser unit assembly Fuser components Hot roll Fuser lamp Sensor(Fuser ou Sensor(Narrow m Fuser solen 3-72 Service Manual
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4062-XXX Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media. Pressure roll The pressure roll is used to apply pressure to the media surface for fusing. Pressure is applied to the media between the pressure roll and heat roll, pressing the melted toner against the media.
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4062-XXX Type 2 fuser unit assembly In the type 2 fuser unit assembly, the detacs, which are used to prevent the media from sticking to the hot roll, do make full contact with the hot roller. The type 2 fuser unit assembly has a life of 150K. Fuser lamp Hot roll Full contact detac Pressure roll Hot roll Full contact detac Pressure roll Exit Sensor (Standard bin exit) The standard media exit ejects printed media from the printer to the standard bin .
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4062-XXX Drive Main drive motor assembly The main drive motor is a DC motor that drives the print cartridge, aligner, MFP and fuser. Redrive motor assembly The redrive motor assembly is a DC motor that drives the redrive assembly that transports the media into the standard bin or output option.
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4062-XXX Electrical components and controller Main cooling fan System card assembly LVPS card assembly Duplex cooling fan Print cartridge cooling fan HVPS card assembly Switch (printer front door interlock) The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt power supply (HVPS) card assembly, printer system card assembly and to the main drive motor assembly, while the printer front door assembly is open.
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4062-XXX System card assembly The system card assembly controls printing operation based on the communication with the RIP controller and optional peripherals. It also controls toner dispense, fuser control, sensor switch feedback, drive motors, clutches and solenoids Control Printhead control Rotation of printhead motor The on/off control of the printhead motor is performed according to the mode of operation as shown below.
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4062-XXX Fuser warm-up The fuser warm-up starts at the time of power on, interlock open or close, jam reset, or return from the low power mode, and ends when the ready temperature is attained, when a failure occurs, or when executing diagnosis.
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4062-XXX Charge The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness. Light striking the drum discharges the surface charge. HVPS (-VDC) Charge roll (-VDC) Ground DRUM Photoconductive Surface Drum Surface Image Drum Surface Voltage -VDC value Conductive Tube Ground 0V Exposure The Printhead generates a beam of laser light.
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4062-XXX This discharge/no discharge process creates an invisible, electrostatic image on the surface of the drum. This image is called a latent image. Modulated Laser Beam Printhead DRUM Drum Surface Image Drum Surface Voltage Laser Beam Laser Beam Discharge Level Invisible Latent Image 0V Development The toner contained within the PC Cartridge has an electrical property that causes it to adhere to the development roll.
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4062-XXX Roll, toner transfers from the Magnet Roll to that point on the drum. There is now a visible toner image on the drum surface. The image is called a developed image. Developer Roll HVPS Metering Blade Toner DRUM -VDC Drum Surface Image Drum Surface Voltage Toner at -VDC Developer Bias value Visible Developed Image 0V Discharge Level Transfer As the paper travels between the transfer Roll and the photoconductor (drum), the Transfer Roll applies a charge to the back of the printing paper.
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4062-XXX is now stuck to the photoconductor (drum) due to the relative electrical differences between the negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper. HVPS -VDC -VDC DRUM Transfer roll Sheet of paper Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process. The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge.
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4062-XXX Auto density sensing Sensor shield assembly Sensor (toner density) The image density sensor assembly uses a reflection type sensor that detects a pre-placed toner patch and image on the photoconductor (drum) and outputs pulses when the central line of the patch image aligns with the central line of the detector. The sensor outputs pulses at the timing the patch image passes the sensor. Therefore, observing changes of intervals at which pulses are output leads to toner density detection.
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4062-XXX High Capacity Input Tray (HCIT) tray assembly Rear media tray guide Media end guide Pick arm assembly Media size actuator Sensor (media empty) Sensor (media low) Sensor (pass through) Sensor (tray raised HP) HCF drawer assembly Tray lift drive motor 3-84 Service Manual
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4062-XXX 250-sheet/550-sheet tray assembly Lockable back restraint Rear media tray guide Media end guide Auto size finger actuator Media size sensing The media size set for the media tray assembly is set by positioning the right media guide, unlocking the slider lock, and sliding the rear paper guide. The rear paper guide triggers the movement of the auto size sensing finger, which then sets the switches of the controller card board.
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4062-XXX Media level sensing The media level for the media tray assembly is triggered by the actuator flag positioned in the two photointerrupter sensors in the pick arm bracket assembly. The actuator flag blocks and unblocks the two sensors in different sequence; it determines whether the paper tray is empty, low, or full.
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4062-XXX The pick arm assembly (autocompensator) is a paper pick device that generates its own normal force. This force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm.
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4062-XXX Pick arm assembly Sensor (media empty) Sensor (media low) 550-sheet drawer assembly 3-88 Service Manual Sensor (pass through)
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4062-XXX Media transport path The following is a cross section of the printer and the tandem tray module, showing the main components directly associated with the media path and transport.
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4062-XXX Models T652 and T654 paper path, rolls, and sensors Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Diverter PC cartridge Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm assembly Functions of main components When the 250 or 550 sheet input trays are installed under the printer, additional trays are available.
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4062-XXX Wear strips The wear strips are designed to provide a fixed resistance to ensure that a single piece of paper is properly fed out of the media tray. There are several types of wear strips available for custom or hard to feed media. Media tray assembly Rear media guide Bottom plate End guide Detection of media size The media size set for the media tray assembly is transmitted to the switch (media size) by moving these guides.
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4062-XXX If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area of the sensor (media empty). The sensor light is transmitted. When the sensing area is blocked (media is present), the signal is off. Sensor (media low) This sensor detects by the actuator position whether media in the media tray assembly is low.
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4062-XXX Duplex Layout of media transport path The main components associated with the media path and transport with the duplex installed.
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4062-XXX Models T652 and T654 duplex paper path Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Diverter PC cartridge Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm assembly Functions of main components When the duplex is installed, duplex (double-sided) printing is available with the printer. The following outlines the functions of the main components of the duplex.
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4062-XXX Duplex drive motor assembly The duplex drive motor assembly transmits driving force to the two duplex media transport roll assemblies and the duplex media center transport roll assembly middle that feeds media.
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4062-XXX Understanding jam numbers and locations When a jam occurs, a message indicating the jam location appears. Open doors and covers and remove trays to access jam locations. To resolve any paper jam message, you must clear all jammed paper from the paper path.
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4062-XXX WARNING: Do not leave the cartridge exposed to light for extended periods. WARNING: The jammed paper may be covered with unfused toner which can stain garments and skin. 5. Remove the jammed paper. CAUTION: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching. Note: If the paper is not easy to remove, then open the rear door and remove the paper from there. 6. Align and reinstall the print cartridge. 7.
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4062-XXX 230 paper jam Rear paper jams 1. Remove the standard tray from the printer. 2. Pull down the bottom rear door.
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4062-XXX 3. Push the tab down. 4. Remove the jammed paper. 5. Close the bottom rear door. 6. Insert the standard tray. 7. Press . Front paper jams 1. Remove the standard tray from the printer. 2. Push the tab down. 1 2 3. Remove the jammed paper. 4. Insert the standard tray. 5. Press .
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4062-XXX 231-239 paper jams (optional external duplex unit) Rear paper jams 1. Push in and hold the latch while pulling up the rear duplex door. 2 1 2. Remove the jammed paper. 3. Close the rear duplex door. 4. Press . Front paper jams 1. Remove the standard tray from the printer. 2. Remove the duplex jam access tray.
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4062-XXX 3. Raise the recessed duplex bar. 4. Remove the jammed paper,. 5. Replace the duplex jam access tray. 6. Insert the standard tray. 7. Press . 241–245 paper jams 1. Pull out the tray indicated on the display. 2. Remove any jammed paper, and then insert the tray. 3. Press . 4. If the jam message remains for a 250-sheet or 550-sheet tray, then remove the tray from the printer. 5. Remove the jammed paper, and then insert the tray. 6. Press .
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4062-XXX 250 paper jam 1. Remove the paper from the multipurpose feeder. 2. Flex the sheets of paper back and forth to loosen them, and then fan them. Do not fold or crease the paper. Straighten the edges on a level surface. 3. Load the paper into the multipurpose feeder. 4. Slide the paper guide toward the inside of the tray until it lightly rests against the edge of the paper. 5. Press 3-102 Service Manual .
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4062-XXX 260 paper jam The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed. 1. Lift the envelope weight, and then remove all the envelopes. 2. If the jammed envelope has entered the printer and cannot be pulled out, then lift the envelope feeder up and then out of the printer, and then set it aside. 3. Remove the envelope from the printer. Note: If you cannot remove the envelope, the print cartridge will have to be removed.
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4062-XXX 280 paper jam 1. Pull down the StapleSmart II Finisher door. 2. Remove the jammed paper. 3. Close the StapleSmart ii Finisher door. 4. Press 3-104 Service Manual .
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4062-XXX 281 paper jam 1. Clear the jam from the stapler output bin. 2. Press . 282 paper jam To prevent paper jams, the stapler motor does not run when the stapler door is open. 1. Close the stapler door until it clicks into place. 2. Press .
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4062-XXX 283 staple jam 1. Press the latch to open the stapler door. 2. Pull the latch of the staple cartridge holder down, and then pull the holder out of the printer. 3. Use the metal tab to lift the staple guard, and then remove any loose staples.
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4062-XXX 4. Press down on the staple guard until it snaps into place. 5. Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place. 6. Close the stapler door. 7. Press .
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4062-XXX Security Reset Jumper The Security Reset Jumper is available on all high-end printer and MFP models, including the T650, T652, T654, X652, X654, X656, and X658. It functions as described below (excerpt from the RIP Functional Spec): Security Reset Jumper Each device contains a hardware jumper with which an administrator can: • Erase all security templates, building blocks, and access controls that a user has defined (i.e.
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4062-XXX 3. Remove the small yellow jumper that covers a pair of the jumper’s pins. Top Rear Front Bottom 4. Replace the small yellow jumper so that it covers the pins adjacent to its original position. 5. Replace and secure the Kensington lock on the card cage (if installed). 6. Power the device on. Note: The movement of the small yellow jumper from position A to position B triggers the reset, not the specific positions.
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4062-XXX 3-110 Service Manual
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4062-XXX 4. Repair Information WARNING: Read the following before handling electronic parts. Handling ESD-sensitive parts Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD).
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4062-XXX Adjustments Polygon and Oscillating printhead mechanical registration adjustment Do the printhead mechanically registration adjustment whenever you remove or replace the printhead or loosen the mounting screws. Install the new printhead with the mounting screws centered in the slots in the printhead frame assembly. Leave the screws loose enough to allow the printhead to move from side to side within the slots.
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4062-XXX 5. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1. The Quick Test Page consists of alignment diamonds, horizontal lines that can be used for mechanical registration adjustment.
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4062-XXX alignment printout is shown below: Lexmark Hd Quick Test Device Information 31 192 MB 467MHz Page Cou nt Installed Memory Processor Speed Serial Number TDS Calibration Engine ID System Card ID 0116413 00 14 FF 00 00 00 00 40 0004007E24A2 Printer Revision Levels Loader Kernel Base Network Netwrk Drvr Engine Panel Font LF.LBH.P055-0 FFN.APS.F191a-0 LF.LBH.P055-0 NF.APS.N179-0 LF.LBH.P055-0 AF.LB.E037-0 9.9 8.31M02-U5.
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4062-XXX 1. Loosen the locknut on the inside rear of the alignment assembly. 2. Remove the two screws holding the alignment assembly to the left side frame. 3. Back the reference adjustment screw 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.
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4062-XXX Step B Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings should be within the range specified in “Registration” on page 3-67. The reference screw can be adjusted without loosening the locknut. Turn the screw a few turns, and print a copy of the Quick Test Page as you check the diamonds on the 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.
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4062-XXX Removals Replacement note: To replace a removed part, reverse the order of removal unless noted otherwise.
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4062-XXX Access door removal (T650, T652, T654) 1. Open the access door. 2. Gently detach the two hinges (A) of the access door from the machine. A 3. Remove the access door. Alignment assembly removal (T650, T652, T654) WARNING: When replacing the alignment assembly, ensure that the media skew is properly adjusted using the adjuster screw (C), or jamming will occur. Go to “Alignment assembly adjustment” on page 4-4. 1. Remove the side cover, left.
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4062-XXX 3. Remove the metal cover. 4. Remove the inner deflector. Go to “Inner deflector removal (T650, T652, T654)” on page 4-25. 5. Remove the MPF pick solenoid assembly. Go to “MPF pick solenoid assembly removal (T650, T652, T654)” on page 4-39. 6. Remove the two screws (B) securing the alignment assembly to the machine. B Note: The adjuster screw (C) requires a hex wrench to loosen and tighten. Note: The adjuster screw (C) can be accessed through the hole (D) in the system card. 7.
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4062-XXX 8. Remove the alignment assembly. D C Replacement Warning: When replacing the alignment assembly, ensure that the media skew is properly adjusted using the adjuster screw (C) or jamming will occur. Go to “Alignment assembly adjustment” on page 4-4.
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4062-XXX Connection access cover, rear removal (T650, T652, T654) 1. Gently detach the two hinges (A) of the connection access cover, rear from the machine. A 2. Remove the connection access cover, rear. Connection bezel assembly, rear removal (T650) 1. Remove the side cover, left. Go to “MPF cam gear removal (T650, T652, T654)” on page 4-37. 2. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on page 4-13. 3.
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4062-XXX Connection bezel assembly, rear removal (T652, T654) 1. Remove the side cover, left. Go to “Side cover, left removal (T652 and T654)” on page 4-66. 2. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower (T652, T654)” on page 4-13. 3. Release the two hooks (A) securing the connection bezel assembly, rear to the machine. A 4. Remove the connection bezel assembly, rear.
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4062-XXX Cover assembly, rear lower removal (T650) 1. Remove the fuser access door assembly. Go to “HVPS card assembly removal (T650, T652, T654)” on page 4-24. 2. Open the rear lower door. 3. Remove the three screws (A) securing the cover assembly, rear lower to the machine. A 4. Remove the cover assembly, rear lower. Cover assembly, rear lower (T652, T654) 1. Open the rear lower door. 2. Remove the four screws (A) securing the cover assembly, rear lower to the machine. A 3.
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4062-XXX Charge roll assembly removal (T650, T652, T654) WARNING: When removing the charge roll assembly, avoid touching the charge roll surface. 1. Open the MPF door assembly. 2. Open the operator panel front cover assembly. 3. Detach the left side of the charge roll assembly from the machine. 4. Detach the right side of the charge roll assembly from the machine. 5. Remove the charge roll assembly. Replacement Warning: When replacing the charge roll assembly, avoid touching the charge roll surface.
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4062-XXX Door assembly, rear removal (T650, T652, T654) 1. Pull the door assembly, rear away from the machine. 2. Twist the door strap left or right until vertical, and pull the strap out of the slot. 3. Position the door assembly, rear at a 45° angle as shown in the picture. 4. Remove the door assembly, rear. Duplex guide assembly, rear removal (T652, T654) 1. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower (T652, T654)” on page 4-13. 2. Remove the media tray. 3.
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4062-XXX 6. Detach the rear duplex guide spring (C). B A C 7. Remove the duplex guide assembly, rear. 8. Remove the screw (D) securing the rear duplex guide handle to the assembly. D 9. Remove the duplex guide assembly, rear. Duplex assembly removal (T652, T654) Note: When removing the duplex drive motor assembly, it does not need to be completely removed from the machine. It may be allowed to gently hang out of the way by the harness. 1. Remove the duplex drive motor assembly.
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4062-XXX 4. Remove the harnesses (B) from the clamp. 5. Disconnect the connection (C) from the duplex assembly. D B C A Note: When removing the duplex assembly, the lower duplex drive belt (D) will become detached. 6. Remove the duplex assembly. Replacement Warning: When replacing the duplex assembly, ensure that the lower duplex drive belt (D) is properly reattached.
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4062-XXX Duplex cooling fan removal (T652, T654) 1. Remove the side cover, right. Go to “Side cover, right removal (T652, T654)” on page 4-68. 2. Remove the screw (A) securing the duplex cooling fan to the machine. 3. Disconnect the connector (B) from the duplex cooling fan. B A 4. Remove the duplex cooling fan. Replacement Warning: When replacing the duplex cooling fan, ensure that it is installed as shown in the picture.
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4062-XXX Duplex drive motor assembly removal (T652, T654) 1. Remove the fuser access door. Go to “HVPS card assembly removal (T650, T652, T654)” on page 4-24. 2. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower (T652, T654)” on page 4-13. 3. Remove the three screws (A) securing the duplex drive motor assembly to the machine. B A Note: When removing the duplex drive motor assembly, the upper duplex drive belt (B) will become detached. 4.
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4062-XXX 7. Remove the harness (E) from the duplex drive motor assembly. E D Replacement Warning: When replacing the duplex drive motor assembly, ensure that all harnesses are properly re-routed. Replacement Note: Ensure the belt is replaced properly. Duplex input sensor assembly removal (T652, T654) 1. Remove the media tray. 2. Gently place the printer on its left or right side. 3. Disconnect the connection (A) from the duplex input sensor assembly. 4.
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4062-XXX Duplex guide assembly, front removal (T652, T654) 1. Remove the media tray. 2. Gently place the printer on its left or right side. 3. Detach the front left duplex guide spring (A) from the duplex guide assembly, front. 4. Detach the front right duplex guide spring (B) from the duplex guide assembly, front. A B 5. Fully open the duplex guide assembly, front 90°, and detach it from the machine. 6. Remove the duplex guide assembly, front.
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4062-XXX Fuser access door assembly removal (T650, T652, T654) 1. Remove the door assembly, rear. Go to “Door assembly, rear removal (T650, T652, T654)” on page 4-15. 2. Press the two tabs (A) on the fuser access door assembly, and detach it from the machine.
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4062-XXX 3. Swing the fuser access door assembly away from the machine. 4. Unsnap the fuser access door assembly from the machine. 5. Remove the fuser access door assembly. Fuser drive release linkage removal (T650, T652, T654) 1. Remove the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 2. Gently unsnap the upper end of the fuser drive release linkage from the machine. 3.
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4062-XXX 5. While pressing the two buttons (A), pull the fuser unit assembly from the machine. B A Replacement Warning: When replacing the fuser unit assembly, ensure that the electrical connection (B) and the two buttons (A) are properly secured. Fuser wiper cover assembly removal (T650, T652, T654) 1. Press the button (A) securing the fuser wiper cover assembly to the machine. A 2. Remove the fuser wiper cover assembly. HVPS card assembly removal (T650, T652, T654) 1. Remove the side cover, right.
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4062-XXX 2. Remove the four screws (A) securing the HVPS card assembly to the machine. 3. Remove the HVPS card assembly. 4. Remove connection (B) and the two high voltage connections (C) from the HVPS card assembly. C B A Replacement Warning: When replacing the HVPS card assembly, ensure that the two high voltage connections (C) are properly replaced. Inner deflector removal (T650, T652, T654) Note: The MPF lift plate assembly can be detached and allowed to hang by the harness.
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4062-XXX 2. Release the two hooks (A) securing the lower portion of the inner deflector to the machine. A 3. Remove the inner deflector. Replacement Warning: When replacing the inner deflector, ensure that it is properly installed, or jamming will occur.
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4062-XXX Laser cover removal (T650, T652, T654) 1. Remove the output cover assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 2. Remove the fuser wiper cover assembly. Go to “Fuser wiper cover assembly removal (T650, T652, T654)” on page 4-24. 3. Remove the side cover, left. Go to “MPF cam gear removal (T650, T652, T654)” on page 4-37 or “Side cover, left removal (T652 and T654)” on page 4-66. 4. Remove the side cover, right.
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4062-XXX WARNING: When removing the laser cover, ensure that the standard bin actuator assembly does not become damaged. 6. Remove the laser cover. LCD screen bezel removal (T650, T652, T654) Gently detach the LCD screen bezel from the operator panel door assembly.
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4062-XXX LVPS card assembly removal (T650) WARNING: When replacing the LVPS card assembly, ensure that the voltage selection switch is set to the proper setting, or damage will occur. 1. Remove the door assembly, rear. Go to “Door assembly, rear removal (T650, T652, T654)” on page 4-15. 2. Remove the side cover, right. Go to “Side cover, right removal (T650)” on page 4-67. 3. Disconnect the connector (A) from the LVPS card assembly. 4. Remove the two screws (B) from the LVPS card assembly. B A B 5.
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4062-XXX 6. Disconnect the connector (C) from the LVPS card assembly. C 7. Remove the LVPS card assembly. Replacement Warning: When replacing the LVPS card assembly, ensure that all connections are replaced. Replacement Warning: When replacing the LVPS card assembly, ensure that the connector pins (D) properly engage the system card. Replacement Warning: When replacing the LVPS card assembly, ensure that the voltage selection switch (E) is set to the proper setting, or damage will occur.
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4062-XXX LVPS card assembly removal (T652, T654) WARNING: When replacing the LVPS card assembly, ensure that the voltage selection switch (E) is set to the proper setting, or damage will occur. 1. Remove the door assembly, rear. Go to “Door assembly, rear removal (T650, T652, T654)” on page 4-15. 2. Remove the side cover, right. Go to “Side cover, right removal (T652, T654)” on page 4-68. 3. Disconnect the connector (A) from the LVPS card assembly. 4. Remove the two screws (B) from the LVPS card assembly.
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4062-XXX 6. Disconnect the connector (C) from the LVPS card assembly. C 7. Remove the LVPS card assembly. Replacement Warning: When replacing the LVPS card assembly, ensure that all connections are replaced. Replacement Warning: When replacing the LVPS card assembly, ensure that the connector pins (D) properly engage the system card. Replacement Warning: When replacing the LVPS card assembly, ensure that the voltage selection switch (E) is set to the proper setting, or damage will occur.
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4062-XXX 2. Remove the six screws (A) securing the metal shield to the machine. A 3. Move the metal shield in the direction of the arrow. 4. Remove the metal shield. 5. Remove the two screws (B) securing the fuser cooling fan to the machine. 6. Remove the fuser cooling fan.
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4062-XXX 7. Remove the fuser cooling fan connection (C). B C Main drive motor assembly removal (T650, T652, T654) 1. Remove the system card assembly. Go to “System card assembly removal (T650, T652, T654, T656)” on page 4-76. 2. Remove the fuser drive release linkage. Go to “Fuser drive release linkage removal (T650, T652, T654)” on page 4-23. 3. Close the operator panel door assembly. 4. Remove the four screws (A) securing the main drive motor assembly to the machine. 5.
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4062-XXX 6. Disconnect the connection (B) from the main drive motor assembly. A B Replacement Warning: Ensure that all electrical connections are properly replaced. Replacement Warning: When replacing the main drive motor assembly, ensure that the operator panel door assembly is in the closed position or the main drive motor assembly will not align properly and damage will occur.
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4062-XXX Media support removal (T650, T652, T654) 1. Gently detach the two bosses (A) of the media support from the machine. A A 2. Remove the media support. Media turn guide removal (T650, T652, T654) 1. Remove the MPF tray door assembly. Go to “MPF tray door assembly removal (T650, T652, T654)” on page 4-41. 2. Gently bend the left side of the media turn guide to release the hook (A) as shown in the picture. A 3.
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4062-XXX MPF cam gear removal (T650, T652, T654) 1. Remove the alignment assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 2. Release the hook (A) securing the gear to the unit. A 3. Remove the MPF cam gear. MPF lift plate assembly removal (T650, T652, T654) 1. Remove the media turn guide. Go to “Media turn guide removal (T650, T652, T654)” on page 4-36. 2. Remove the four screws (A) securing the MPF lift plate assembly to the machine. 3.
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4062-XXX 5. Remove the MPF lift plate assembly. Replacement Warning: When replacing the MPF lift plate assembly, ensure that the lever (C) is held down when reinstalling the MPF lift plate assembly, or damage will occur. Replacement Warning: When replacing the MPF lift plate assembly, ensure that the MPF pick solenoid assembly does not become damaged. MPF media out actuator removal (T650, T652, T654) 1. Remove the media turn guide. Go to “Media turn guide removal (T650, T652, T654)” on page 4-36. 2.
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4062-XXX MPF pick solenoid assembly removal (T650, T652, T654) Note: The MPF lift plate assembly can be detached and allowed to hang by the harness. The connection does not need to be disconnected. 1. Remove the MPF lift plate assembly. Go to “MPF lift plate assembly removal (T650, T652, T654)” on page 4-37. 2. Remove the side cover, left. Go to “MPF cam gear removal (T650, T652, T654)” on page 4-37 or “Side cover, left removal (T652 and T654)” on page 4-66. 3.
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4062-XXX 5. Remove the screw (B) securing the MPF pick solenoid assembly to the machine. B 6. Remove the MPF pick solenoid assembly. 7. Disconnect the connection (C) from the MPF pick solenoid assembly.
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4062-XXX MPF tray door assembly removal (T650, T652, T654) 1. Open the operator panel door assembly. 2. Open the MPF tray door assembly, and position it as shown in the picture. 3. Gently release the two bosses (A) from the slots (B).
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4062-XXX 4. While holding the MPF tray in its uppermost position, swing the MPF tray door assembly away from the machine to detach the MPF tray from the machine.
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4062-XXX 5. Slide the MPF tray door assembly in the direction of the arrow to detach it from the machine. 6. Remove the MPF tray door assembly. Operator panel latch assembly removal (T650, T652, T654) 1. Open the operator panel door assembly. 2. Remove the four screws (A) securing the operator panel latch assembly to the machine.
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4062-XXX 3. Release the two hooks (B). B B A 4. Remove the operator panel latch assembly. Operator panel door assembly removal (T650, T652, T654) Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
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4062-XXX 4. Detach the operator panel door assembly from the machine. 5. Remove the black plastic cover. 6. Remove the two screws (C) securing the USB socket to the assembly. 7. Remove the USB socket. 8. Disconnect the connector (D) from the assembly. C D Operator panel hinge assembly, left removal (T650, T652, T654) 1. Remove the operator panel door assembly. Go to “Operator panel door assembly removal (T650, T652, T654)” on page 4-44. 2.
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4062-XXX 5. Remove the harnesses (C) from the operator panel hinge assembly, left. C A B 6. Detach the spring (D) from the operator panel hinge assembly, left. 7. Detach the spring (E) from the operator panel hinge assembly, left. 8. Remove the E-clip (F) from the operator panel hinge assembly, left. 9. Remove the pin (G) from the operator panel hinge assembly, left.
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4062-XXX 10. Remove the operator panel hinge assembly, left. Operator panel hinge assembly, right removal (T650, T652, T654) 1. Remove the operator panel door assembly. Go to “Operator panel door assembly removal (T650, T652, T654)” on page 4-44. 2. Detach the spring (A) from the operator panel hinge assembly, right. 3. Detach the spring (B) from the operator panel hinge assembly, right. B A 4. Remove the E-clip (C) from the operator panel hinge assembly, right.
PAGE 370
4062-XXX 5. Remove the pin (D) from the operator panel hinge assembly, right. C 6. Remove the operator panel hinge assembly, right.
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4062-XXX Operator panel door assembly removal (models X651, X652, X654, and X656) Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
PAGE 372
4062-XXX 6. Remove eight screws (E) securing the scanner controller cage cover to the cage. An X658 model is represented in the graphic below, however, the card cage cover removal procedure is similar for all models. E E 7. Remove the printer controller card cage cover. 8. Disconnect the USB cable and the cover closed interlock switch harness.
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4062-XXX 9. Lift the operator panel door assembly out of the machine.
PAGE 374
4062-XXX Operator panel cover latch assembly removal (models X651, X652, X654, and X656) 1. Lift the operator panel cover assembly. 2. Remove the ten screws (A) securing the operator panel cover latch assembly to the operator panel cover assembly. 3. Remove the operator panel cover latch assembly. Option drive shaft removal (T650, T652, T654) 1. Gently place the printer on its left or right side. 2. Using pliers, gently pull the option drive shaft from the machine.
PAGE 375
4062-XXX 3. Remove the spring. A Replacement Warning: When replacing the option drive shaft, ensure that the plastic hook (A) is not damaged, or the option drive shaft will not remain secured.
PAGE 376
4062-XXX Output cover assembly removal (T650, T652, T654) 1. Unsnap the output cover assembly from the machine. 2. Remove the output cover assembly. Pick arm assembly removal (T650, T652, T654) 1. Remove the media tray from the machine. 2. Place the machine on the left or right side. 3. Remove the spring (A).
PAGE 377
4062-XXX 4. Remove the two E-clips (B) securing the pick arm assembly to the machine.
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4062-XXX 5. Remove the screw (C) securing the pick arm assembly to the machine. C 6. Remove the band (D) from the pick arm assembly. 7. Remove the cover from the pick arm assembly. 8. Remove the three connections (E) from the pick arm assembly. 9. Remove the wiring harness (F) from the pick arm assembly. F E D 10. Remove the pick arm assembly. Replacement Warning: When replacing the pick arm assembly, ensure that the harnesses are properly rerouted.
PAGE 379
4062-XXX Pick roll assembly removal (T650, T652, T654) 1. Remove the media tray. 2. Gently pull the pick arm assembly down, and release the two hooks (A) securing the two pick roll assemblies. A A 3. Remove the two pick roll assemblies. Replacement Warning: When replacing the pick roll assembly, do not touch the rubber surface. Print cartridge cooling fan removal (T650, T652, T654) 1. Remove the side cover, right.
PAGE 380
4062-XXX Print cartridge clamp assembly removal (T650, T652, T654) Note: This procedure can be applied to the left or right printer cartridge hold down assembly. 1. Remove the laser cover. Go to “Laser cover removal (T650, T652, T654)” on page 4-27. 2. Remove the screw (A) securing the print cartridge clamp assembly to the machine. B A 3. Remove the print cartridge clamp assembly.
PAGE 381
4062-XXX Print cartridge ID connector assembly removal (T650, T652, T654) 1. Remove the print cartridge. 2. Remove the main drive motor assembly. Go to “Output cover assembly removal (T650, T652, T654)” on page 4-54. 3. Release the two hooks (A) securing the print cartridge ID connector assembly to the machine. A 4. Remove the print cartridge ID connector assembly. 5. Disconnect the connection (B) from the print cartridge ID connector assembly.
PAGE 382
4062-XXX Printhead assembly removal (T650) Note: When replacing the printhead assembly, ensure that the printhead is properly calibrated, or print quality issues will occur. Go to “Alignment assembly adjustment” on page 4-4. 1. Remove the laser cover. Go to “Laser cover removal (T650, T652, T654)” on page 4-27. 2. Remove the six screws (A) securing the metal cover to the machine. A A 3. Remove the metal cover. 4. Disconnect the connections (B) from the printhead assembly.
PAGE 383
4062-XXX 5. Remove the three screws (C) securing the printhead assembly to the machine. C 6. Remove the printhead assembly. Replacement Warning: When replacing the printhead assembly, ensure that the printhead is properly calibrated, or print quality issues will occur. Printhead assembly removal (T652, T654) WARNING: When replacing the printhead assembly, ensure that the printhead skew is properly adjusted, or print quality issues will occur. 1. Remove the laser cover.
PAGE 384
4062-XXX 3. Remove the metal cover. 4. Disconnect the connections (B) from the printhead assembly. B 5. Remove the four screws (C) securing the printhead assembly to the machine. C 6. Remove the printhead assembly. Replacement Warning: When replacing the printhead assembly, ensure that the printhead skew is properly adjusted, or print quality issues will occur. Redrive assembly removal (T650, T652, T654) 1. Remove the door assembly, rear.
PAGE 385
4062-XXX 5. While pressing the two tabs (B), pull the redrive assembly from the machine. B A B Redrive motor assembly removal (T652, T654) 1. Remove the laser cover. Go to “Laser cover removal (T650, T652, T654)” on page 4-27. 2. Remove the six screws (A) securing the metal cover to the machine.
PAGE 386
4062-XXX 3. Remove the metal cover. 4. Disconnect the connection (B) from the redrive motor assembly. B 5. Disconnect the connection (C) from the sensor (standard media bin full).
PAGE 387
4062-XXX 6. Release the hooks (D) securing the output option interface cable assembly to the machine. D C 7. Detach the output option cable assembly. 8. Remove the two screws (E) securing the redrive motor assembly to the machine. E 9. Remove the redrive motor assembly. Side cover, left removal (T650) 1. Open the MPF tray door assembly. 2. Open the operator panel door assembly.
PAGE 388
4062-XXX 3. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on page 4-13. 4. Remove the four screws (A) securing the side cover, left to the machine. A A 5. Swing the side cover, left away from the machine. 6. Remove the side cover, left. Side cover, left removal (T652 and T654) 1. Open the MPF tray door assembly. 2. Open the operator panel door assembly. 3. Remove the cover assembly, rear lower.
PAGE 389
4062-XXX 4. Remove the four screws (A) securing the side cover, left to the machine. A A 5. Swing the side cover, left away from the machine. 6. Remove the side cover, left. Side cover, right removal (T650) 1. Open the operator panel door assembly. 2. Open the MPF tray door assembly. 3. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on page 4-13.
PAGE 390
4062-XXX 4. Remove the five screws (A) securing the side cover, right to the machine. A A 5. Remove the side cover, right. Side cover, right removal (T652, T654) 1. Open the operator panel door assembly. 2. Open the MPF tray door assembly. 3. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower (T652, T654)” on page 4-13. 4. Remove the five screws (A) securing the side cover, right to the machine. A A 5. Remove the side cover, right. Sensor (duplex input) removal (T652, T654) 1.
PAGE 391
4062-XXX 2. Release the hooks (A) securing the senor (duplex media path) to the bracket. A 3. Remove the sensor (duplex input).
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4062-XXX Sensor (media level) removal (T650, T652, T654) 1. Remove the pick arm assembly. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. 2. Release the hooks (A) securing the sensor (media level) to the assembly. A 3. Remove the sensor (media level). Sensor (media out) removal (T650, T652, T654) 1. Remove the pick arm assembly. Go to “Operator panel door assembly removal (models X651, X652, X654, and X656)” on page 4-49. 2.
PAGE 393
4062-XXX Sensor (toner empty) removal (T650, T652, T654) 1. Remove the HVPS card assembly. Go to “HVPS card assembly removal (T650, T652, T654)” on page 4-24. 2. Remove the screw (A) securing the sensor (toner empty) to the machine. 3. Remove the sensor (toner empty). 4. Disconnect the connection (B) from the sensor (toner empty). B A Sensor (input) removal (T650, T652, T654) 1. Remove the inner deflector. Go to “Inner deflector removal (T650, T652, T654)” on page 4-25. 2.
PAGE 394
4062-XXX 4. Disconnect the connection (B) from the sensor (input). Sensor shield assembly removal (T650, T652, T654) 1. Remove the inner deflector. Go to “Inner deflector removal (T650, T652, T654)” on page 4-25. 2. Gently unsnap the sensor shield assembly from the machine. A 3. Remove the sensor shield assembly. Replacement Warning: When replacing the sensor shield assembly, ensure that the spring (A) is properly aligned and the sensor shield assembly opens and closes properly.
PAGE 395
4062-XXX Sensor (standard bin exit) removal (T650, T652, T654) 1. Remove standard bin actuator assembly. Go to “Sensor (standard bin exit) removal (T650, T652, T654)” on page 4-73. 2. Release the hooks (A) securing the sensor (standard bin exit) to the assembly. A 3. Remove the sensor (standard bin exit). Sensor (toner density) removal (T650, T652, T654) 1. Remove the sensor shield assembly. Go to “Sensor shield assembly removal (T650, T652, T654)” on page 4-72. 2.
PAGE 396
4062-XXX 3. Press the tab (B) to release the standard bin actuator assembly from the machine. A B 4. Remove the standard bin actuator assembly. Switch (media size) assembly removal (T650, T652, T654) 1. Remove the side cover, left. Go to “MPF cam gear removal (T650, T652, T654)” on page 4-37 or “Side cover, left removal (T652 and T654)” on page 4-66. 2. Remove the six screws (A) securing the metal cover to the machine. A 3. Remove the metal cover. 4. Remove the media tray. 5.
PAGE 397
4062-XXX 6. Release the two hooks (B) securing the switch (media size) assembly to the machine. B C 7. Remove the switch (media size) assembly. 8. Disconnect the connection (C) from the switch (media size) assembly.
PAGE 398
4062-XXX System card assembly removal (T650, T652, T654, T656) Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
PAGE 399
4062-XXX 4. Remove the metal shield. WARNING: When disconnecting all the electrical connections, ensure that the connectors and harnesses do not become damaged. 5. Disconnect all connections from the system card assembly. Note: There are two fine thread screws and four course thread screws securing the system card assembly to the machine, ensure that these screws are properly reinstalled. 6. Remove the six screws (B) securing the system card assembly to the machine.
PAGE 400
4062-XXX WARNING: When removing the system card assembly from the machine, ensure that the LVPS assembly connection (C) does not become damaged. B C 7. Remove the system card assembly. 8. Remove any remaining screws securing the system card assembly to the metal box. 9. Remove the system card assembly. Replacement Warning: Ensure that all ground wires are properly replaced.
PAGE 401
4062-XXX 3. Gently unsnap the transfer roll assembly from the machine. 4. Remove the transfer roll assembly. Replacement Warning: When replacing the transfer roll assembly, do not touch the foam surface. Transfer roll bracket assembly, left removal (T650, T652, T654) 1. Remove the transfer roll assembly. Go to “Transfer roll assembly removal (T650, T652, T654)” on page 4-78. 2. Remove the inner deflector. Go to “Inner deflector removal (T650, T652, T654)” on page 4-25. 3.
PAGE 402
4062-XXX 9. Remove the ground wire (F). C D B F E A Replacement Warning: When reinstalling the transfer roll bracket assembly, left, ensure that the bushing (C), spring (D), and ground wire (F) are properly replaced. Transfer roll bracket assembly, right removal (T650, T652, T654) 1. Remove the transfer roll assembly. Go to “Transfer roll assembly removal (T650, T652, T654)” on page 4-78. 2. Remove the inner deflector. Go to “Inner deflector removal (T650, T652, T654)” on page 4-25. 3.
PAGE 403
4062-XXX 2. Gently unsnap the transfer deflector from the machine. 3. Remove the transfer deflector. 4. Remove the screw (A) securing the ground wire to the transfer deflector. A 5. Remove the ground wire. Replacement Warning: When replacing the transfer deflector, ensure that the ground wire is properly replaced. Tray roller catch assembly removal (T650, T652, T654) 1. Remove the media tray. 2. Remove the HVPS card assembly. Go to “HVPS card assembly removal (T650, T652, T654)” on page 4-24. 3.
PAGE 404
4062-XXX 4. Remove the tray roller catch assembly from the machine.
PAGE 405
4062-XXX Option removals Repair Information 4-83
PAGE 406
2-XXX 5-bin mailbox rear door assembly removal 1. Open the rear door assembly and twist the rear door strap vertical and remove the strap. 2. Pry the rear door hinges out of the bottom hinges and remove.
PAGE 407
4062-XXX 5-bin mailbox left outer cover removal 1. Open the rear door assembly. 2. Grasp the upper rear corner of the left outer cover and pull it off the 5-bin mailbox assembly. 5-bin mailbox left inner cover removal 1. Remove the 5-bin mailbox rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85.
PAGE 408
4062-XXX 3. Remove the single screw (A) on the top and the four screws (B) on the inside of the left inner cover. A B 4. Remove the 5-bin mailbox left inner cover. 5-bin mailbox right outer cover removal 1. Open the rear door assembly. 2. Grasp the upper rear corner of the right outer cover and pull it off the 5-bin mailbox assembly.
PAGE 409
4062-XXX 5-bin mailbox right inner cover removal 1. Remove the 5-bin mailbox rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. Remove the 5-bin mailbox right outer cover. Go to “5-bin mailbox right outer cover removal” on page 4-86. 3. Remove the three screws (A) securing the right inner cover to the 5-bin mailbox assembly. A 4. Remove the 5-bin mailbox right inner cover.
PAGE 410
4062-XXX 5-bin mailbox top cover removal 1. Open the rear door assembly. 2. Remove the cable cover panel by lifting up on the right side and pull to the right and out. 3. Remove the two screws (A) on each side of the top cover. A 4. Pull the left side up first and carefully unroute the cables from the channels and then remove the top cover.
PAGE 411
4062-XXX 5-bin mailbox media bin full actuator removal 1. Remove the 5-bin mailbox left inner cover. Go to “5-bin mailbox left inner cover removal” on page 4-85. 2. Grasp the media bin full actuator and pull the pins from the bosses.
PAGE 412
4062-XXX 5-bin mailbox sensor (pass through) removal 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. If the lower pass through sensor needs to be removed, first remove the 5-bin mailbox rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 3. Lift up the deflector gate above the sensor (pass through) and using a flat-blade screwdriver, release the tabs securing the sensor. 4.
PAGE 413
4062-XXX 5-bin mailbox sensor (media bin empty) removal 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Release the connecting tabs on the sensor (media bin empty) and remove from its bracket. 3. Disconnect the harness from the sensor (media bin empty).
PAGE 414
4062-XXX 5-bin mailbox controller card assembly removal 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Disconnect all the harnesses from the 5-bin mailbox controller card assembly. 3. Remove the two screws (A) securing the controller card assembly to the 5-bin mailbox assembly. A 4. Remove the 5-bin mailbox controller card assembly.
PAGE 415
4062-XXX 5-bin mailbox static brush mylar assembly removal 1. Remove the 5-bin mailbox top cover. Go to “5-bin mailbox top cover removal” on page 4-88. 2. Carefully flex the 5-bin mailbox static brush mylar assembly to detach the hinges on each side. 3. Remove the 5-bin mailbox static brush mylar assembly.
PAGE 416
4062-XXX 5-bin mailbox media bin fifth deflector removal 1. Remove the rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. With a spring hook, carefully remove the upper deflector gate spring and for ease of reassembly, temp 3. Temporarily hook the spring to the upper frame tab. 4. Unsnap each side of the deflector gate and remove. Replacement Note: The static brush mylar assembly is attached to the media bin fifth deflector.
PAGE 417
4062-XXX 5-bin mailbox media bin first through fourth deflector removal 1. Remove the rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. Using a springhook, remove the deflector spring from the deflector. 3. Unsnap each side of the deflector and remove. Replacement Note: The static brush mylar assembly is attached to the media bin fifth deflector. Do not forget to reinstall it on the new deflector.
PAGE 418
4062-XXX 5-bin mailbox media bin extension assembly removal 1. Fully extend the media bin extension. 2. Release the two tabs on the underside of the extension and pull out the rest of the way. 5-bin mailbox deflector gate solenoid removal 1. Remove the 5-bin mailbox right outer cover. Go to “5-bin mailbox right outer cover removal” on page 4-86. 2. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 3. Remove the top cable cover panel.
PAGE 419
4062-XXX 4. Remove the screw (A) securing the appropriate 5-bin mailbox deflector gate solenoid. A 5. Remove and unroute the cable to the deflector gate solenoid. 6. Disconnect the proper deflector gate solenoid harness from the controller card. Note: To ease the cable unrouting, cut the appropriate cable.
PAGE 420
4062-XXX 5-bin mailbox transport solenoid removal 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Disconnect J15 at the controller card. 3. Remove the screw (A) securing the 5-bin mailbox transport solenoid to the left frame. A 4. Remove the 5-bin mailbox transport solenoid.
PAGE 421
4062-XXX 5-bin mailbox sensor (deflector gate HP) removal 1. Remove the 5-bin left inner cover. Go to “5-bin mailbox left inner cover removal” on page 4-85. 2. Remove the following harnesses from the controller card: J14 A and B, J2, and J11. 3. Remove the two screws (A) securing the controller card assembly and move the card to the side.
PAGE 422
4062-XXX 4. Remove the four screws (B) securing the left frame assembly to the 5-bin mailbox assembly. B 5. Move the left frame assembly out of the way. 6. Remove the 5-bin mailbox sensor (deflector gate HP) by pressing the tabs.
PAGE 423
4062-XXX 7. Disconnect the harness from the 5-bin mailbox sensor (deflector gate HP). 250-sheet option tray assembly Note: Carefully remove the base machine from the input option tray assembly before proceeding. 250-sheet media tray assembly removal Note: This removal procedure can be applied to 250-sheet option drawer assembly.
PAGE 424
4062-XXX Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly. 250-sheet pick arm bracket assembly removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Disconnect the two 250-sheet pick arm bracket assembly cable connectors from the 250-sheet controller card assembly. 2. Detach the pick arm spring from the drawer.
PAGE 425
4062-XXX 3. Remove the three screws (A) securing the 250-sheet pick arm bracket assembly to the drawer. A 4. Remove the 250-sheet pick arm bracket assembly.
PAGE 426
4062-XXX 250-sheet media out actuator removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Remove the 250-sheet pick arm bracket assembly. Go to “250-sheet pick arm bracket assembly removal” on page 4-102. 2. Release the hook (A) securing the 250-sheet media out actuator to the 250-sheet pick arm bracket assembly. A 3. Remove the 250-sheet media out actuator from the drawer.
PAGE 427
4062-XXX 4. Remove the four screws (A) securing the 250-sheet frame assembly to the drawer. A 5. Remove the 250-sheet frame assembly.
PAGE 428
4062-XXX 250-sheet controller card assembly removal 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Disconnect the three connectors from the 250-sheet controller card assembly. 3. Remove the three screws (B) securing the 250-sheet controller card assembly to the 250-sheet frame. A 4. Remove the 250-sheet controller card assembly.
PAGE 429
4062-XXX 550-sheet option tray assembly Note: Carefully remove the base machine from the input option tray assembly before proceeding. 550-sheet media tray assembly removal Note: This removal procedure can be applied to 550-sheet option drawer assembly. Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly.
PAGE 430
4062-XXX 550-sheet pick arm bracket assembly removal 1. Remove the 550-sheet media tray assembly. Go to “Media out actuator removal (models T652 and T654)” on page 4-158. 2. Remove the two 550-sheet pick arm bracket assembly cable connectors (A) from the 550-sheet controller card assembly. 3. Detach the 550-sheet bellcrank recoil spring (B) from the drawer. 4. Remove the four screws (C) securing the 550-sheet pick arm bracket assembly to the drawer. A 5. Remove the 550-sheet pick arm bracket assembly.
PAGE 431
4062-XXX 550-sheet bellcrank recoil spring removal 1. Remove the 550-sheet pick arm bracket assembly. Go to “550-sheet pick arm bracket assembly removal” on page 4-108. 2. Remove the 550-sheet bellcrank recoil spring from the 550-sheet pick arm bracket assembly. 550-sheet frame assembly removal Note: The 550-sheet frame assembly is not a FRU. 1. Remove the 550-sheet pick arm bracket assembly. Go to “550-sheet pick arm bracket assembly removal” on page 4-108. 2.
PAGE 432
4062-XXX 4. Remove the four screws (A) securing the 550-sheet frame assembly to the drawer.
PAGE 433
4062-XXX 5. Remove the 550-sheet frame assembly. 550-sheet controller card assembly removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-159. 2. Disconnect the three connectors from the 550-sheet controller card assembly.
PAGE 434
4062-XXX 3. Remove the three screws (A) securing the 550-sheet controller card assembly to the 550-sheet frame. A 4. Remove the 550-sheet controller card assembly.
PAGE 435
4062-XXX 550-sheet option drive shaft with spring removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-159. 2. Pinch the two hooks (A) on the cap, and detach it from the 550-sheet frame. 3. Pull the drive roll gear (B), the shaft with spring (C), and the bevel out through the opening. A A B C A 4. Remove the 550-sheet option drive shaft with spring.
PAGE 436
4062-XXX 2. Turn the drawer upside down, and unsnap the two hooks (A) securing the anti-tip latch assembly to the drawer with a flathead screwdriver. Note: The hooks might break when detaching the anti-tip assembly from the drawer. A 3. Remove the anti-tip latch assembly. High capacity input tray (HCIT) Note: Carefully remove the HCIT from the base machine and the caster base before proceeding.
PAGE 437
4062-XXX High capacity input tray (HCIT) media tray assembly removal 1. Open the HCIT media tray assembly until it reaches a stop. 2. Press the latches (A) on the left and right sides of the HCIT tray slides. A A 3. Slide the HCIT media tray assembly out of the drawer.
PAGE 438
4062-XXX High capacity input tray (HCIT) tray cover, front removal 1. Open the HCIT media tray assembly until it reaches a stop. 2. Remove the six screws (A) securing the HCIT tray cover, front to the HCIT media tray assembly.
PAGE 439
4062-XXX A 3. Remove the HCIT tray cover, front.
PAGE 440
4062-XXX High capacity input tray (HCIT) cover, rear removal 1. Remove the HCIT media tray assembly. Go to “High capacity input tray (HCIT) media tray assembly removal” on page 4-115. 2. Remove the four screws (A) securing the HCIT cover, rear to the drawer.
PAGE 441
4062-XXX 3. Remove the HCIT cover, rear.
PAGE 442
4062-XXX High capacity input tray (HCIT) cover, right removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. Note: Before removing the HCIT right cover, first remove the right side anti-tip latch assembly. Go to “High capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-123. 1. Remove the High capacity input tray (HCIT) cover, rear. Go to “High capacity input tray (HCIT) cover, rear removal” on page 4-118. 2.
PAGE 443
4062-XXX 3. Remove the HCIT cover, right.
PAGE 444
4062-XXX High capacity input tray (HCIT) cover, left removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. Note: Before removing the HCIT cover, left, first remove the left side anti-tip latch assembly. Go to “High capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-123. 1. Remove the HCIT cover, rear. Go to “High capacity input tray (HCIT) cover, rear removal” on page 4-118. 2.
PAGE 445
4062-XXX 3. Remove the HCIT cover, left. High capacity input tray (HCIT) anti-tip latch assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. The left and right anti-tip latch assemblies are the same, and only one is in a package. The instructions below are for removing the left latch; removing the right latch has similar instructions.
PAGE 446
4062-XXX 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122. Note: The left side anti-tip assembly will come off when removing the HCIT cover, left. High capacity input tray (HCIT) drawer slide assembly removal The left and right drawer slide assemblies are the same, and only one is in a package. The instructions below are for removing the left slide; removing the right slide has similar instructions. 1. Remove the HCIT media tray assembly.
PAGE 447
4062-XXX 3. Remove the HCIT drawer slide. High capacity input tray (HCIT) tray lift drive motor assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, right. Go to “High capacity input tray (HCIT) cover, right removal” on page 4-120. 2. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122. 3.
PAGE 448
4062-XXX 5. Remove the HCIT tray lift drive motor assembly. High capacity input tray (HCIT) controller card assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122. 2. Disconnect all connectors from the HCIT controller card assembly.
PAGE 449
4062-XXX 3. Remove the three screws (A) securing the HCIT controller card assembly. A 4. Remove the HCIT controller card assembly and the shield. High capacity input tray (HCIT) media size actuator assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT controller card assembly. Go to “High capacity input tray (HCIT) controller card assembly removal” on page 4-126. 2. Disconnect the two springs (A) from the frame.
PAGE 450
4062-XXX 4. Snap loose the actuator switch (C) and remove. C 5. Remove the four screws (D) securing the card mount option with the media size actuator to the frame.
PAGE 451
4062-XXX 6. Remove the card mount option with the media size actuator. Re-installation note: 1. Re-install the card mount option with the media size actuator to the frame by inserting the leftmost part of it through the hole, and then securing it with the four screws. 2. Re-install the actuator switch with the spring to the card mount option through the drawer opening. 3. Re-install the cam size sensing plate with the spring to the card mount option through the access hole in the rear side. 4.
PAGE 452
4062-XXX High capacity input tray (HCIT) pick arm bracket assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122. 2. Remove the HCIT pick arm bracket assembly cable connectors from the HCIT controller card assembly. Note: Remove the cable from the restraint, and observe the routing for reinstallation. 3. Remove the pick arm lift spring from the drawer.
PAGE 453
4062-XXX 4. Remove the five screws (A) securing the HCIT pick arm bracket assembly. A 5. Remove the HCIT pick arm bracket assembly from the drawer by slightly lifting and removing it.
PAGE 454
4062-XXX High capacity input tray (HCIT) tray closed latch with spring removal The left and right tray closed latches with springs are the same, and only one is in a package. The instructions below are for removing the left latch; removing the right latch has similar instructions. 1. Remove the HCIT media tray assembly. Go to “High capacity input tray (HCIT) media tray assembly removal” on page 4-115. 2.
PAGE 455
4062-XXX 3. Remove the rear door assembly from the hinges by gently prying the hinges off the bosses.
PAGE 456
4062-XXX High capacity stacker right cover removal 1. Remove the high capacity stacker rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-132. 2. Using a #1 phillips screwdriver, remove the three screws (A) securing the right cover to the high capacity stacker assembly. A 3. Remove the right cover.
PAGE 457
4062-XXX High capacity stacker left cover removal 1. Remove the high capacity stacker rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-132. 2. Using a #1 phillips screwdriver, remove the three screws (A) securing the left cover to the high capacity stacker assembly. A 3. Remove the left cover.
PAGE 458
4062-XXX High capacity stacker media output bin assembly removal 1. Remove both the high capacity stacker media output bin recoil springs. 2. Remove the high capacity stacker standard output bin LED. 3. Carefully spread the left side of the high capacity stacker assembly and maneuver the media output bin from the assembly.
PAGE 459
4062-XXX High capacity stacker controller card cover panel removal 1. Remove the media output bin assembly. Go to “High capacity stacker media output bin assembly removal” on page 4-136. 2. Remove the two screws (A) securing the controller card cover panel on the rear of the assembly. 3. Remove the screw (B) securing the ground strap to the right frame. 4. Flex the controller card cover panel by grasping the bottom middle of the panel and lifting it, releasing the tabs (C) from the left and right frame.
PAGE 460
4062-XXX High capacity stacker switch (media bin HP) removal 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-137. 2. Remove the two screws (A) securing the high capacity stacker switch (media bin HP) to the left frame. A 3. Disconnect the high capacity stacker switch (media bin HP) harness from the upper controller card. 4. Remove the high capacity stacker switch (media bin HP).
PAGE 461
4062-XXX High capacity stacker sensor (media bin full) assembly removal 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-137. 2. Release the tabs securing the high capacity stacker sensor (media bin full) assembly to the left frame. 3. Disconnect the sensor (media bin full) harness from the upper controller card. 4. Remove the high capacity stacker sensor (media bin full) assembly.
PAGE 462
4062-XXX 3. Remove the bracket from the frame and disconnect the sensor (media bin full) and media bin full actuator. High capacity stacker controller card assembly (upper and lower) removal 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-137. 2. Disconnect the harnesses from the controller card. Note: Pay careful attention to where the power input and output harnesses are attached. 3.
PAGE 463
4062-XXX High capacity stacker right frame removal 1. Remove the right media output bin recoil spring. 2. Remove the four screws (A) securing the right frame to the high capacity stacker assembly. 3. Carefully remove the right frame. A Note: When installing the right frame, make sure the media output bin assembly is aligned properly.
PAGE 464
4062-XXX High capacity stacker left frame removal 1. Remove the left media output bin recoil spring. 2. Remove the two screws (A) securing the switch (media bin HP) to the left frame. 3. Remove the high capacity stacker standard output bin LED. 4. Remove the four screws (B) securing the left frame to the high capacity stacker assembly. B A 5. Carefully remove the left frame.
PAGE 465
4062-XXX Note: When installing the left frame, make sure the media output bin assembly is aligned properly. High capacity stacker upper deflector gate removal 1. Remove the rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-132. 2. With a spring hook, carefully remove the upper deflector gate spring and for ease of reassembly, temporarily hook the spring to the upper frame tab.
PAGE 466
4062-XXX 3. Unsnap each side of the deflector gate and remove. High capacity stacker sensor (pass through) removal 1. Remove the rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-132. 2. Using needle-nose pliers or your finger, pull out and downward on the sensor (pass through) until the sensor unsnaps. 3. Remove the high capacity controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-137.
PAGE 467
4062-XXX 4. Disconnect the sensor (pass through) harness from the controller card and remove the sensor.
PAGE 468
4062-XXX High capacity stacker left mounting bracket removal 1. Remove the high capacity stacker left cover. “High capacity stacker left cover removal” on page 4-135. 2. Remove the eight screws (A) securing the high capacity stacker left mounting bracket. A 3. Pull the bracket up and let it rest on the assembly with the cables intact.
PAGE 469
4062-XXX High capacity stacker sensor (deflector gate HP) removal 1. Remove the high capacity stacker left mounting bracket. Go to “High capacity stacker left mounting bracket removal” on page 4-146. 2. Remove the harness from the sensor. 3. Unclip the sensor tabs and remove.
PAGE 470
4062-XXX Installing / Removing the RFID UHF option 1. RFID UHF option components: 1. RFID UHF Option 2. Firmware card 3. User Flash card 4. Fuser wiper 5. Interface card, plastic tee, screw 6. RFID cable 7. Documentation CD 2. Unplug the power cord from the electrical outlet, and then disconnect all cables from the printer.
PAGE 471
4062-XXX 3. Open the system board door, and loosen the screw on the system board cover. Remove the cover. 4. Install the firmware card into the system board.
PAGE 472
4062-XXX 5. Install the flash card into the system board.
PAGE 473
4062-XXX 6. Remove the metal cover from the system card opening. 7. Locate the interface card mounting area on the system board.
PAGE 474
4062-XXX 8. Snap the plastic tee card holder into place on the system board. 9. Angle the interface card through the connector opening. 10. Insert the interface card into the plastic tee card holder.
PAGE 475
4062-XXX 11. Insert the long thumbscrew into the hole in the interface card. Turn it just enough to hold the card in place. Do not tighten yet. 12. Insert the screws to secure the mounting bracket to the system board. 13. Tighten the thumbscrew, and insert the interface card plug into the blue connector on the system board.
PAGE 476
4062-XXX 14. Replace the system board cover. 15. Lift the printer off the 250/550 sheet optional drawer, place the RFID option on top of the drawer, and place the printer on top of the RFID option.
PAGE 477
4062-XXX 16. Unpack the RFID cable, and attach between the RFID option and the interface card. Reconnect all printer cables. 17. Remove the old fuser wiper (or blank).
PAGE 478
4062-XXX 18. Install the new wiper. Turn the printer on. 1 2 19. To remove the RFID UHF option, reverse the order of installation. Lower interface cable assembly removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-159. 2. Disconnect the lower interface cable connector (A) from the 550-sheet controller card. 3. Pinch the options auto connect (B) to separate the lower interface cable assembly from the 550-sheet frame. B A 4.
PAGE 479
4062-XXX Media size actuator removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Remove the 250-sheet controller card assembly. Go to “250-sheet controller card assembly removal” on page 4-106. 2. Remove the screw (A) securing the media size actuator to the 250-sheet frame. A 3. Remove the media size actuator.
PAGE 480
4062-XXX Media tray catch spring removal 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Turn the drawer upside down to access the media tray catch spring. 3. Release the media tray catch spring. Media out actuator removal (models T652 and T654) 1. Remove the 550-sheet pick arm bracket assembly. Go to “550-sheet pick arm bracket assembly removal” on page 4-108. 2.
PAGE 481
4062-XXX Media size actuator removal 1. Remove the 550-sheet controller card assembly. Go to “550-sheet controller card assembly removal” on page 4-111. 2. Remove the screw (A) securing the media size actuator to the 550-sheet frame. A 3. Remove the media size actuator. Media tray catch spring removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-159. 2. Turn the drawer over so that you can access the media tray catch spring. 3. Release the media tray catch spring.
PAGE 482
4062-XXX 1. Remove the media tray catch spring. Go to “Media tray catch spring removal” on page 4-159. 2. Remove the tray roller catch assembly from the drawer.
PAGE 483
4062-XXX Output expander rear door assembly removal 1. Open the rear door assembly. 2. Hold the door to approximately 45° angle, and force out the left hinge and slide the right hinge out to remove the door. Output expander left outer cover removal 1. Remove the output expander rear door assembly. Go to “Output expander rear door assembly removal” on page 4-161. 2. Grasp the lower rear corner of the left outer cover and pull out to remove.
PAGE 484
4062-XXX Output expander left inner cover removal 1. Remove the output expander left outer cover. Go to “Output expander left outer cover removal” on page 4-161. 2. Remove the screw (A) securing the left inner cover. A 3. Holding the rear of the left inner cover, pull out while simultaneously separating it from the option. Output expander right outer cover removal 1. Remove the output expander rear door assembly. Go to “Output expander rear door assembly removal” on page 4-161. 2.
PAGE 485
4062-XXX Output expander right inner cover removal 1. Remove the output expander right outer cover. Go to “Output expander right outer cover removal” on page 4-162. 2. Remove the screw (A) securing the right inner cover to the unit. A 3. At the rear of the right inner cover, pull out from the option and remove the right inner cover. Output expander media bin latch (left and right) removal 1. Remove the output expander left or right inner cover.
PAGE 486
4062-XXX Output expander media output bin assembly removal 1. Remove the left and right output expander media bin latches. Go to “Output expander media bin latch (left and right) removal” on page 4-163. 2. Remove the standard output bin LED. Go to “Output expander sensor (pass through) removal” on page 4-169. 3. Rotate the output bin assembly downward and out of the slots to remove. Output expander media bin full actuator removal 1. Remove the output expander left inner cover.
PAGE 487
4062-XXX Output expander sensors (media bin full) assembly removal 1. Remove the output bin left inner cover. Go to “Output expander left inner cover removal” on page 4-162. 2. Untwist the sensor harnesses from the cable guide. 3. Release the tabs securing the sensors (media bin full) and remove. Replacement Note: Be sure to replace the sensors in the correct order. Make sure their positions are not switched. 4. Remove the output expander controller card cover panel.
PAGE 488
4062-XXX Output expander sensor (media bin full) bracket assembly removal 1. Remove the output expander left inner cover. Go to “Output expander left inner cover removal” on page 4-162. 2. Grasp the sensor bracket and pull away from the option while releasing the tab. 3. If replacing the bracket, remove the sensors (media bin full) from the bracket. Replacement Note: Be sure to replace the sensors in the correct order. Make sure their positions are not switched.
PAGE 489
4062-XXX 2. Remove the screw (A) on the back side of the option. A 3. Remove the grounding screw (B) on the right output option frame guide the grounding cable through the hole in the frame. 4. Carefully flex the panel from the lower middle and pull the four tab (C) out of the frame and remove.
PAGE 490
4062-XXX Output expander controller card removal 1. Remove the output expander controller card cover panel. Go to “Output expander controller card cover panel removal” on page 4-166. 2. Disconnect all harnesses from the controller card. 3. Remove the two screws (A) securing the controller card to the frame. A 4. Remove the controller card. Replacement Note: Be sure to replace the interface connectors in their proper orientation as the two have common connection pins.
PAGE 491
4062-XXX Output expander sensor (pass through) removal 1. Remove the output expander controller card cover panel. Go to “Output expander controller card cover panel removal” on page 4-166. 2. Release the tabs securing the sensor (pass through). 3. Remove the sensor harness from the controller card. 4. Pull the connector harness through the frame and remove.
PAGE 492
4062-XXX Output expander deflector gate removal 1. Use a spring hook to disconnect the upper end of the deflector gate spring. 2. Temporarily hook the upper end of the deflector gate spring to the left frame. 3. Pull the deflector gate out of its hinges and remove.
PAGE 493
4062-XXX Output expander sensor (deflector gate HP) removal 1. Remove the output expander left inner cover. Go to “Output expander left inner cover removal” on page 4-162. 2. Remove the four screws securing the left frame assembly to the option. 3. Pull the left frame assembly out far enough to gain access to the sensor (deflector gate HP). 4. Release the tabs securing the sensor (deflector gate HP) and remove. 5. Disconnect the harness to the sensor and remove.
PAGE 494
4062-XXX SFP stapler assembly rear door assembly removal 1. Open the rear door assembly. 2. Force the left hinge out of the slot by pushing the door to the right. 3. Once the left hinge has been disengaged, pull the right hinge out. 4. Remove the rear door assembly. SFP stapler assembly right cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the right cover. A 2. Pull out on the front side of the right cover to disengage the tabs. 3. Remove the right cover.
PAGE 495
4062-XXX SFP stapler assembly left cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. A 2. Pull out on the front side of the left cover to disengage the tabs. 3. Remove the left cover.
PAGE 496
4062-XXX SFP stapler assembly top cover removal 1. Remove the left and right cover. Go to “SFP stapler assembly left cover removal” on page 4-173 and “SFP stapler assembly right cover removal” on page 4-172. 2. Remove the two screws (A) from the left and right side of the top cover. A 3. Pull up and toward the front to remove the top cover.
PAGE 497
4062-XXX SFP stapler assembly handle cover removal 1. Remove the left and right cover. Go to “SFP stapler assembly left cover removal” on page 4-173 and “SFP stapler assembly right cover removal” on page 4-172. 2. Remove two screws (A) from each side of the SFP stapler assembly. A A 3. Lift up and to the rear to remove the cover.
PAGE 498
4062-XXX SFP stapler assembly LED sensor cover removal 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. A 2. Remove the output bin LED. Go to “SFP stapler assembly standard output bin LED and LED clear lens removal” on page 4-178. 3. Remove the sensor (finisher bin media present).
PAGE 499
4062-XXX 4. Remove the LED sensor cover. SFP stapler assembly sensor (finisher bin media present) removal 1. Remove the LED sensor cover. Go to “SFP stapler assembly LED sensor cover removal” on page 4-176. 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. A 3. Remove the harness connected to the media bin present sensor. 4. Remove the sensor (finisher bin media present).
PAGE 500
4062-XXX SFP stapler assembly standard output bin LED and LED clear lens removal 1. Remove the LED sensor cover. Go to “SFP stapler assembly LED sensor cover removal” on page 4-176. 2. Remove the two screws (A) securing the LED to the cover. A 3. Remove the LED and disconnect the harness. 4. Remove the LED clear lens.
PAGE 501
4062-XXX SFP stapler assembly tamper drive belt removal 1. Remove the tamper recoil spring. Go to “SFP stapler assembly tamper drive belt removal” on page 4-179. 2. Pull the belt out the tamper belt holder and remove the belt from the pulley.
PAGE 502
4062-XXX SFP stapler assembly tamper drive motor assembly removal 1. Remove the top cover. Go to “SFP stapler assembly top cover removal” on page 4-174. 2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley. 3. Disconnect the tamper driver motor harness from the controller card. 4. Remove the two screws (A) securing the tamper drive motor assembly to the tamper frame. A 5. Remove the tamper drive motor assembly.
PAGE 503
4062-XXX SFP stapler assembly media stack flap and media stack flap actuator removal 1. Remove the handle cover. Go to “SFP stapler assembly handle cover removal” on page 4-175. 2. Release the locking tab and slide the media stack flap actuator to the right and remove.
PAGE 504
4062-XXX SFP stapler assembly stapler unit assembly removal 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-172. 2. Remove the four cable harnesses attached to the stapler unit assembly. 3. Remove the three screws (A) securing the stapler unit assembly. 4. Remove the stapler unit assembly.
PAGE 505
4062-XXX SFP stapler assembly paddle drive motor assembly removal 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-173. 2. Disconnect the paddle motor harness from the controller card. 3. Remove the cable from the harness clip. 4. Remove the two screws (A) securing the two paddle drive motor assemblies. A 5. Remove the paddle drive motor assembly.
PAGE 506
4062-XXX SFP stapler assembly sensor (media stack) removal 1. Remove the top cover. Go to “SFP stapler assembly top cover removal” on page 4-174. 2. Disconnect the harness to the sensor (media stack). 3. Using your fingers, pinch tab (A) securing the sensor (media stack) and remove.
PAGE 507
4062-XXX SFP stapler assembly sensor (paddle HP) removal 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-173. 2. Disconnect the harness to the sensor (paddle home position). 3. Using your fingers, pinch tab (A) securing the sensor (paddle home position) and remove.
PAGE 508
4062-XXX SFP stapler assembly sensor (stapler access door interlock) removal 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-172. 2. Disconnect the harness to the sensor (stapler access door interlock). 3. Using your fingers, pinch tab (A) securing the sensor (stapler access door interlock) and remove.
PAGE 509
4062-XXX SFP stapler assembly sensor (tamper HP left and right) removal 1. Remove the SFP stapler assembly top cover. Go to “SFP stapler assembly top cover removal” on page 4-174. 2. Disconnect the harness to the SFP stapler assembly sensor (tamper HP left and right). 3. Using your fingers, pinch the tabs (A) securing the staple finisher sensor (tamper HP left and right) and remove.
PAGE 510
4062-XXX SFP stapler assembly sensor (bin full send) removal 1. Remove the stapler/stacker controller card assembly. Go to “Stapler/stacker controller card assembly removal” on page 4-192. 2. Remove the two screws (A) securing the staple finisher sensor (bin full send). A 3. Disconnect the harness and remove.
PAGE 511
4062-XXX SFP stapler assembly sensor (bin full receive) removal 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-172. 2. Remove the two screws (A) securing the sensor (bin full receive). A 3. Disconnect the harness and remove. SFP stapler assembly sensor (media in stapler) removal 1. Remove the stapler unit assembly from the. Go to “SFP stapler assembly stapler unit assembly removal” on page 4-182. 2.
PAGE 512
4062-XXX 3. Using needlenose pliers, carefully grip the sensor and pull it out and disconnect the harness. Replacement Notes: Using needlenose pliers, place the rear most tab in the sensor bracket first. Then push on the rear face of the sensor until the other two tabs snap into place. SFP stapler assembly sensor (deflector HP) removal 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-173. 2. Disconnect the harness to the sensor (deflector HP).
PAGE 513
4062-XXX 3. Release the tabs (A) securing the sensor to the unit. A Note: The tabs may be difficult to access. The use of a spring hook or flat-blade screwdriver may be necessary to release the tabs.
PAGE 514
4062-XXX Stapler/stacker controller card assembly removal 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-173. 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. A 4. Remove the stapler/stacker controller card assembly. Sensor (HCIT tray raised HP) with cable assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1.
PAGE 515
4062-XXX 2. Disconnect the sensor (HCIT tray raised HP) cable connector from the HCIT controller card assembly. Note: Remove the cable from the restraints, and observe the routing for reinstallation.
PAGE 516
4062-XXX 3. Remove the screw (A) securing the sensor to the rear frame. 4. Release the hooks (B) securing the sensor to the rear frame. B A 5. Remove the sensor (HCIT tray raised HP).
PAGE 517
4062-XXX Sensor (HCIT pass through) with cable removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122. 2. Disconnect the sensor (HCIT pass through) cable connector from the HCIT controller card assembly. Note: Remove the cable restraint, and observe the routing for reinstallation. 3. Release the hooks (A) securing the sensor (HCIT pass through) to the machine.
PAGE 518
4062-XXX Sensor (pass through) with cable removal 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Disconnect the sensor (pass through) cable connector from the 250-sheet controller card. 3. Remove the sensor (pass through) with cable. Sensor (pass through) with cable removal 1. Remove the 550-sheet frame assembly. Go to “550-sheet frame assembly removal” on page 4-109. 2.
PAGE 519
4062-XXX 2. Remove the tray roller catch assembly from the drawer. Tray roller catch assembly removal 1. Remove the media tray catch spring. Go to “Media tray catch spring removal” on page 4-158. 2. Remove the tray roller catch assembly from the drawer. Upper interface cable assembly removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-159. 2. Disconnect the upper interface cable connector (A) from the 550-sheet controller card.
PAGE 520
4062-XXX 3. Release the two hooks (B) securing the options auto connect to the 550-sheet frame. B A 4. Remove the upper interface cable assembly.
PAGE 521
4062-XXX 5. Connector locations and connections Connections A wiring diagram showing connector locations will be inserted here at a later date.
PAGE 522
4062-XXX 5-2 Service Manual
PAGE 523
4062-XXX 6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Following these recommendations can help prevent problems and maintain optimum performance. Safety inspection guide The purpose of this inspection guide is to aid you in identifying unsafe conditions. If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you correct the hazard.
PAGE 524
4062-XXX Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at required maintenance intervals. It is necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and reliability of the printer.
PAGE 525
4062-XXX 7. Parts catalog How to use this parts catalog The following legend is used in the parts catalog: AsmIndex Part number Units/mach - OR Units/option Units/ kit or pkg Description • Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 • • • • • • and the item number 1. Part number: identifies the unique number that identifies this FRU. Units/mach: refers to the number of units actually used in the base machine or product.
PAGE 526
4062-XXX Assembly 1: Covers 7-2 Service Manual
PAGE 527
4062-XXX Assembly 1: Covers AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4332 1 1 Door assembly, rear (T650) 1 40X4329 1 1 Door assembly, rear (T652) 1 40X4331 1 1 Door assembly, rear (T654 and T656) 2 40X4334 1 1 Cover assembly, rear lower (T650) 2 40X4335 1 1 Cover assembly, rear lower (T652, T654, and T656) 3 40X4338 1 1 Side cover, right (T650) 3 40X1862 1 1 Side cover, right (T652) 3 40X4337 1 1 Side cover, right (T654) 3 40X7033 1
PAGE 528
4062-XXX Assembly 2: T650, T652, and T654 Operator panel 7-4 Service Manual
PAGE 529
4062-XXX Assembly 2: T650, T652, and T654 Operator panel AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4366 1 1 Operator panel cable assembly (T650, T652, and T654) 2 40X4462 1 1 Operator panel door assembly (T650, T652, and T654) 3 40X4380 2 1 Counterbalance spring (T650, T652, and T654) 4 40X4397 1 1 Operator panel hinge assembly, right (T650, T652, and T654) 5 40X4616 1 1 Operator panel latch assembly (T650, T652, and T654) 6 40X4396 1 1 Operator p
PAGE 530
4062-XXX Assembly 3: T656dne Operator panel, MPF and smart card 7-6 Service Manual
PAGE 531
4062-XXX Assembly 3: T656 Operator panel, MPF and smart card AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X7039 1 1 Card reader cable assembly (T656) 2 40X1972 1 1 Inner cover, right (T656) 3 40X2045 1 1 Operator panel cable assembly (T656) 4 40X2089 1 1 MPF tray door assembly (T656) 5 40X2077 2 1 Counterbalance spring (T656) 6 40X2078 2 1 Spring connector (T656) 7 40X4631 1 1 Operator panel door latch assembly (T656) 8 40X2051 1 1 USB cable
PAGE 532
4062-XXX Assembly 4: Drive motor assemblies and duplex 7-8 Service Manual
PAGE 533
4062-XXX Assembly 4: Drive motor assemblies and duplex AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4465 1 1 Redrive assembly (T650) 1 40X4466 1 1 Redrive assembly (T652) 1 40X4467 1 1 Redrive assembly (T654 and T656) 2 40X4344 1 1 Duplex drive motor assembly (T652, T654, and T656) 3 40X4346 1 5 Duplex assembly with 2 belts and 2 pulleys (T652, T654, and T656) 4 40X4351 1 1 Duplex guide handle (T652, T654, and T656) 5 40X4352 1 1 Duplex guide, r
PAGE 534
4062-XXX Assembly 5: Media path and ducts 12 1 12 11 10 2 9 2 8 7 4 3 5 6 7-10 Service Manual
PAGE 535
4062-XXX Assembly 5: Media path and ducts AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4384 1 1 EP cooling fan duct 2 40X4390 4 1 Machine pad 3 40X1869 1 1 Transfer deflector with static brush 4 40X1889 1 1 Duplex deletion assembly (T652, T654) 5 40X4387 1 1 Inner deflector (T650) 5 40X4388 1 1 Inner deflector (T652, T654, and T656) 6 40X1900 1 1 Media turn guide with actuator 7 40X4385 1 1 Envelope feeder interface cover 8 40X4406 2 1
PAGE 536
4062-XXX Assembly 6: Printhead, charge, and transfer 7-12 Service Manual
PAGE 537
4062-XXX Assembly 6: Printhead, charge, and transfer AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4464 1 2 Printhead with cable assembly (T652 and T654) 1 40X7040 1 1 Printhead with cable assembly (T656) 2 40X1865 1 1 Printhead cable (T652, T654, and T656) 3 40X4463 1 2 Printhead with cable assembly (T650) 4 40X4367 1 1 Printhead cable assembly (T650) 5 40X4317 1 1 Charge roll link spring, right 6 40X1893 1 4 Charge roll arm assembly with cable,
PAGE 538
4062-XXX Assembly 7: Pick arm assembly, trays, and MPF 7-14 Service Manual
PAGE 539
4062-XXX Assembly 7: Pick arm assembly, trays, and MPF AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4394 1 1 Tray catch spring 2 40X4395 1 1 Tray roller catch assembly 3 40X4365 1 1 MPF pick solenoid assembly 4 40X4457 1 1 MPF cam gear 5 40X1883 4 1 MPF pick roll assembly with flanges and clip 6 40X4458 1 1 MPF lift plate assembly (T650) 6 40X4459 1 1 MPF lift plate assembly (T652, T654, and T656) 7 40X4460 1 1 MPF tray door assembly (T650)
PAGE 540
4062-XXX Assembly 8: LVPS, fuser and electrical cables 1 7-16 Service Manual
PAGE 541
4062-XXX Assembly 8: LVPS, fuser and electrical cables 1 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X1870 1 1 100V type 1 fuser assembly 1 40X4418 1 1 110V type 1 fuser assembly 1 40X1871 1 1 220V type 1 fuser assembly 1 40X5853 1 1 100V type 2 fuser assembly 1 40X5854 1 1 110V type 2 fuser assembly 1 40X5855 1 1 220V type 2 fuser assembly 2 40X4419 1 1 Fuser interface cable assembly 3 40X4355 1 1 LVPS card assembly 4 40X4359 1 1 Prin
PAGE 542
4062-XXX Assembly 9: HVPS, system card, and electrical cables 2 7-18 Service Manual
PAGE 543
4062-XXX Assembly 9: HVPS, system card, and electrical cables 2 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4383 1 1 Cleaning blade contact 2 40X4381 1 1 Drum grounding contact 3 40X4382 1 1 Print cartridge HV contact 4 40X4370 1 1 Sensor (toner empty) 5 40X4362 1 1 HVPS card assembly 6 40X4361 1 1 HVPS / sensor cable assembly 7 40X4368 1 1 Sensor (input) 8 40X4358 1 1 Envelope / input option tray cable assembly 9 40X5911 1 1 System c
PAGE 544
4062-XXX Assembly 10: 250 Sheet option tray assembly 1 7 3 6 5 2 4 18 8 17 16 15 14 9 10 13 11 12 7-20 Service Manual
PAGE 545
4062-XXX Assembly 10: 250 Sheet option tray assembly AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4569 1 1 Complete 250 sheet option tray assembly 2 40X3447 1 1 250 Sheet pick arm bracket assembly 3 40X3448 1 1 250 Sheet bellcrank recoil spring 4 40X4308 2 1 Pick roll assembly (2) 5 40X4369 1 1 Sensor (media low) 6 40X4369 1 1 Sensor (media empty) 7 40X4309 1 1 250 Sheet media out actuator 8 40X4570 1 1 Anti-tip latch assembly 9 40X3453
PAGE 546
4062-XXX Assembly 11: 550 Sheet option tray assembly 1 7 3 6 2 5 4 18 8 17 16 15 14 9 10 13 11 12 7-22 Service Manual
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4062-XXX Assembly 11: 550 Sheet option tray assembly AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4576 1 1 Complete 550 sheet option tray assembly 2 40X3454 1 1 550 Sheet pick arm bracket assembly 3 40X4307 1 1 550 Sheet bellcrank recoil spring 4 40X4308 1 2 Pick roll assembly (2) 5 40X4369 1 1 Sensor (media low) 6 40X4369 1 1 Sensor (media empty) 7 40X4310 1 1 550 Sheet media out actuator 8 40X4570 2 2 Anti-tip latch assembly 9 40X3957
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4062-XXX Assembly 12: HCIT Sheet option tray assembly 1 3 8 7 4 6 2 5 9 22 10 21 11 20 18 19 12 14 15 14 15 17 16 7-24 Service Manual 13
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4062-XXX Assembly 12: HCIT Sheet option tray assembly AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4579 1 1 Complete HCIT option tray assembly 2 40X4590 1 2 HCIT pick arm bracket assembly 3 40X4595 1 1 Pick arm sensor cable assembly 4 40X4591 1 1 HCIT bellcrank recoil spring 5 40X4308 2 2 Pick roll assembly (2) 6 40X4369 2 1 Sensor (media low) 7 40X4310 1 1 550 Sheet media out actuator 8 40X4369 2 1 Sensor (media empty) 9 40X4581 1 1 H
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4062-XXX Assembly 13: SFP stapler assembly #1 1 7-26 Service Manual
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4062-XXX Assembly 13: SFP stapler assembly # 1 AsmIndex 1 Part number 40X5547 Units/ mach Units/ kit or pkg 1 1 Description SFP stapler assembly (comes completely assembled) Parts catalog 7-27
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4062-XXX Assembly 14: SFP stapler assembly #2 1 17 16 15 2 13 3 14 6 12 7 10 11 8 9 7-28 Service Manual 5 4
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4062-XXX Assembly 14: SFP stapler assembly #2 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4612 1 1 Handle cover 2 40X4613 1 1 Rear door assembly 3 40X5910 1 1 Stapler cover 4 40X4610 1 1 Right cover 5 40X5544 1 1 Sensor (bin full receive) 6 40X4617 1 2 Finisher bin spring 7 40X5545 1 1 Standard output bin LED 8 40X5727 1 1 LED clear lens 9 40X5720 1 1 LED sensor cover 10 40X4618 1 1 Sensor (finisher bin media present) 11 40X461
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4062-XXX Assembly 15: SFP stapler assembly #3 1 11 2 3 10 6 4 5 8 6 7 9 7-30 Service Manual
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4062-XXX Assembly 15: SFP stapler assembly #3 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4645 1 1 Media stack flap actuator 2 40X4646 1 1 Media stack flap 3 40X4369 1 1 Sensor (media stack) 4 40X4621 1 1 Left tamper motor assembly 5 40X4622 1 1 Right tamper motor assembly 6 40X4624 1 2 Tamper recoil spring 7 40X4369 1 1 Sensor (tamper HP right) 8 40X4369 1 1 Sensor (tamper HP left) 9 40X4623 1 1 Tamper drive belt 10 40X4369 1 1
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4062-XXX Assembly 16: SFP stapler assembly #4 1 2 7-32 Service Manual
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4062-XXX Assembly 16: SFP stapler assembly #4 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X4641 1 1 Stapler assembly 2 40X5909 1 1 Sensor (media in stapler) Parts catalog 7-33
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4062-XXX Assembly 17: 5-bin mailbox #1 1 2 14 3 13 12 10 11 9 7 5 6 8 7-34 Service Manual 4
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4062-XXX Assembly 17: 5-bin mailbox #1 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X5550 1 1 Complete 5 bin mailbox unit assembly 2 40X5708 1 1 Top cover 3 40X5709 1 1 Rear door assembly 4 40X5712 1 1 Right outer cover 5 40X5713 1 1 Right inner cover 6 40X5756 1 1 Output bin LED bracket 7 40X5717 1 1 Output bin LED assembly 8 40X5714 1 1 Standard output bin LED bracket 9 40X5755 1 1 LED clear lens 10 40X4773 1 1 Standard output bi
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4062-XXX Assembly 18: 5-bin mailbox #2io 1 2 3 4 5 6 4 5 6 4 5 12 6 4 5 6 4 7 11 10 7 8 8 9 7-36 Service Manual
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4062-XXX Assembly 18: 5-bin mailbox #2 AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X5550 1 1 Complete 5 bin mailbox unit assembly 2 40X0028 1 1 Spring (top) 3 40X2036 1 1 Deflector gate (top) 4 40X4772 1 1 Static brush mylar assembly 5 40X2037 1 1 Deflector gate 6 40X2065 1 1 Spring 7 40X3242 1 1 Sensor (pass through) 8 40X2061 5 1 Deflector gate solenoid 9 40X4369 1 1 Sensor (deflector gate HP) 10 40X3240 1 1 Sensor (media bin em
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4062-XXX Assembly 19: High capacity stacker 1 2 3 19 18 16 20 4 17 8 5 6 7 14 8 13 15 11 5 9 10 12 7-38 Service Manual
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4062-XXX Assembly 19: High capacity stacker AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X5730 1 1 Complete high capacity stacker assembly 2 40X5737 1 1 Rear door assembly 3 40X1988 1 1 Deflector gate 4 40X3264 2 1 Sensor (pass through) 5 40X5733 1 1 High capacity output controller card assembly 6 40X5734 1 1 Right frame 7 40X5735 1 1 Right cover 8 56P4210 1 2 Media output bin recoil spring 9 40X4773 1 1 Standard output bin LED 10 40X
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4062-XXX Assembly 20: Output expander 1 18 15 2 16 3 17 19 4 14 5 13 11 12 5 6 9 8 10 7-40 Service Manual 7
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4062-XXX Assembly 20: Output expander AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X5719 1 1 Complete output expander assembly 2 40X5722 1 1 Rear door assembly 3 40X1988 1 1 Deflector gate 4 40X3264 1 1 Sensor (pass through) 5 40X1991 2 1 Output expander media bin latch 6 40X5726 1 1 Right inner cover 7 40X5725 1 1 Right outer cover 8 40X5755 1 1 LED clear lens 9 40X4773 1 1 Standard output bin LED 10 40X1998 1 1 Media bail assembl
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4062-XXX Assembly 21: Envelope feeder and external duplex 1 2 7-42 Service Manual
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4062-XXX Assembly 21: Envelope feeder and external duplex AsmIndex Part number Units/ mach Units/ kit or pkg Description 1 40X5739 1 1 Envelope feeder (T650, T652, and T654 only - will not fit the T656) 2 40X5904 1 1 External duplex Parts catalog 7-43
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4062-XXX Assembly 22: RFID UHF Option assembly 1 D E C F B G A AsmIndex 1 Part number 40X1483 Units/ mach Units/ kit or pkg 1 1 Description US RFID UHF option assembly including: A. RFID UHF option B. Firmware card C. User flash card D. Fuser wiper E. Interface card, plastic tee, screw F. RFID cable G. Documentation CD 1 40X1484 1 1 EU RFID UHF option assembly including: A. RFID UHF option B. Firmware card C. User flash card D. Fuser wiper E. Interface card, plastic tee, screw F.
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4062-XXX Assembly 23: Miscellaneous AsmIndex Part number Units/ mach Units/ kit or pkg Description NS 40X5903 1 1 Relocation kit NS 40X4723 1 1 Printer maintenance kit (100 V type 1 fuser) NS 40X4724 1 1 Printer maintenance kit (110 V type 1 fuser) NS 40X4765 1 1 Printer maintenance kit (220 V type 1 fuser) NS 40X4766 1 1 Printer maintenance kit (100 V type 2 fuser) NS 40X4767 1 1 Printer maintenance kit (110 V type 2 fuser) NS 40X4768 1 1 Printer maintenance kit (220
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4062-XXX AsmIndex Part number Units/ mach Units/ kit or pkg Description NS 40X4823 1 1 Parallel 1284-B interface card NS 40X1367 1 1 10-Foot parallel printer cable NS 40X2665 1 1 Fuser oil wiper (black housing) NS 40X2666 1 1 Fuser wax wiper (gray housing) NS 40X1368 1 1 2-Meter USB printer cable NS 40X1462 1 1 Locking universal media drawer with tray, 200 sheet NS 40X1463 1 1 Locking media drawer with tray, 550 sheet NS 40X1464 1 1 Locking universal media drawer
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4062-XXX Assembly 24: Power cords AsmIndex Part number Units/ mach Units/ kit or pkg Description NS 40X0269 1 1 Power cord LV, USA & Canada, Latin America NS 40X0288 1 1 Power cord HV, Argentina NS 40X1766 1 1 Power cord HV, Bolivia & Peru NS 40X0273 1 1 Power cord HV, Chile, Uruguay NS 40X3141 1 1 Power cord HV, Paraguay, Austria, Belgium, France, Germany, Italy, Netherlands, Bluemark, Czech & Solvic countries, Greece, Hungary, Medmark 1, Medmark 2, Arabic, Poland, Russia, CIS
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4062-XXX Assembly 25: Universal trays and accessories AsmIndex NS Part number 40X5857 Units/ mach Units/ kit or pkg 1 1 Description Universal media drawer with tray, 200 sheet NS 40X5858 1 1 Universal media tray, 200 sheet NS 40X5859 1 1 Universal media drawer with tray, 400 sheet NS 40X5860 1 1 Universal media tray, 400 sheet NS 40X5945 1 1 33” banner drawer with tray NS 40X5946 1 1 33” banner tray NS 40X5947 1 1 48” banner drawer with tray NS 40X7007 1 1 48” banne
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4062-XXX Index Numerics 5-bin mailbox output sensor test 3-18 A acronyms 1-9, 3-89 adjustments fuser solenoid 4-6 gap adjustment 4-6 B Button Test 3-8, 3-36 buttons accessing service menus 3-2, 3-30 Button Test 3-8, 3-36 C Clear Custom Status 3-58 code update 3-2 Configuration ID 3-20, 3-45 configuration menu accessing 3-2, 3-25, 3-30, 3-49 available menus 3-25, 3-49 Demo Mode 3-27 Disk Encryption 3-56 Energy Conserve 3-28, 3-54 Env Prompts 3-28 Envelope Prompts 3-55 Factory Defaults 3-28, 3-54 Font Sha
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4062-XXX REGISTRATION 3-33 Quick Test 3-34 diagnostics mode 3-3 accessing 3-2 available tests 3-3 BASE SENSOR TEST 3-19 DUPLEX TESTS Duplex Feed 1 3-14 Duplex Feed 2 3-14 Motor Test 3-14 Quick Test 3-12 Sensor Test 3-13 Top Margin 3-13 EP SETUP Auto Dark Adj 3-22 Charge Roll 3-22 EP Defaults 3-21 Fuser Page Count 3-21 Fuser Temp 3-21 Gap Adjust 3-22 Print Contrast 3-22 Transfer 3-21 Warm Up Time 3-21 EVENT LOG Clear Log 3-24 Display Log 3-23 Print Log 3-23 exiting 3-5 FINISHER TESTS Feed Test 3-18 Sensor T
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4062-XXX skew 2-173 spots 2-169 vertical stripes 2-165 input sensor tray tests 3-15, 3-41 input source tests 3-7, 3-35 input tray feed test 3-15, 3-40 J Jobs On Disk 3-55 K Key Repeat Initial Delay 3-58 Key Repeat Rate 3-58 L Left Margin duplex 3-39 LES Applications 3-58 Lexmark Embedded Solution 3-58 lithium battery ii-xxi, 4-76 lubrication specifications 6-1 M maintenance ESD-sensitive parts 4-1 lubrication 6-1 maintenance kit 6-2 safety inspection guide 6-1 maintenance approach 1-1 menus accessing s
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4062-XXX duplex 3-13, 3-38 simplex (front side) 3-5, 3-33 U unique tools 1-8, 3-88 upper front cover parts catalog 7-2 USB speed 3-59 W warm up time 3-21, 3-46 Wipe Disk 3-57 Wiper Message 3-58 I-4 Service Manual
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4062-XXX Part number index P/N 40X0028 40X0269 40X0271 40X0273 40X0275 40X0288 40X0301 40X0303 40X1367 40X1368 40X1385 40X1462 40X1463 40X1464 40X1483 40X1484 40X1556 40X1592 40X1593 40X1594 40X1766 40X1772 40X1773 40X1774 40X1791 40X1792 40X1862 40X1863 40X1863 40X1864 40X1865 40X1866 40X1868 40X1869 40X1870 40X1871 40X1876 40X1883 40X1884 40X1886 40X1887 40X1888 40X1889 40X1892 40X1893 40X1900 40X1971 40X1972 40X1973 40X1988 40X1989 40X1990 Description Page Spring (top) - - - - - - - - - - - - - - -
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4062-XXX 40X1991 40X1998 40X2036 40X2037 40X2038 40X2045 40X2051 40X2061 40X2065 40X2077 40X2078 40X2089 40X2665 40X2666 40X2786 40X2787 40X2788 40X2862 40X2863 40X3141 40X3240 40X3242 40X3264 40X3265 40X3265 40X3447 40X3448 40X3449 40X3453 40X3454 40X3609 40X3822 40X3854 40X3957 40X4302 40X4303 40X4304 40X4305 40X4306 40X4307 40X4307 40X4308 40X4309 40X4309 40X4310 40X4310 40X4311 40X4313 40X4314 40X4316 40X4317 40X4318 40X4319 40X4320 40X4321 40X4322 40X4323 Output expander media bin latch - - - - - -
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4062-XXX 40X4324 Side cover, left (T650) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 40X4325 Side cover, left (T652) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 40X4326 Output cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3 40X4329 Door assembly, rear (T652) - - - - -
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4062-XXX 40X4385 40X4386 40X4387 40X4388 40X4389 40X4390 40X4391 40X4392 40X4394 40X4395 40X4395 40X4396 40X4397 40X4406 40X4415 40X4417 40X4418 40X4419 40X4457 40X4458 40X4459 40X4460 40X4461 40X4462 40X4463 40X4464 40X4465 40X4466 40X4467 40X4468 40X4469 40X4470 40X4471 40X4472 40X4473 40X4473 40X4474 40X4494 40X4569 40X4570 40X4571 40X4572 40X4574 40X4575 40X4576 40X4578 40X4579 40X4580 40X4581 40X4582 40X4583 40X4584 40X4585 40X4586 40X4587 40X4588 40X4589 40X4590 40X4591 Envelope feeder interface cov
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4062-XXX 40X4592 40X4593 40X4594 40X4595 40X4596 40X4602 40X4603 40X4604 40X4609 40X4610 40X4611 40X4612 40X4613 40X4615 40X4616 40X4617 40X4618 40X4619 40X4621 40X4622 40X4623 40X4624 40X4625 40X4626 40X4627 40X4628 40X4629 40X4630 40X4631 40X4641 40X4645 40X4646 40X4697 40X4723 40X4724 40X4765 40X4766 40X4767 40X4768 40X4772 40X4773 40X4819 40X4822 40X4823 40X4826 40X4827 40X5038 40X5039 40X5057 40X5301 40X5302 40X5303 40X5316 40X5541 40X5544 40X5545 40X5547 40X5550 40X5551 HCIT controller card assembly
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4062-XXX 40X5704 40X5708 40X5709 40X5710 40X5711 40X5712 40X5713 40X5714 40X5717 40X5718 40X5719 40X5720 40X5721 40X5722 40X5723 40X5724 40X5725 40X5726 40X5727 40X5729 40X5730 40X5731 40X5733 40X5734 40X5735 40X5736 40X5737 40X5739 40X5746 40X5747 40X5748 40X5749 40X5753 40X5755 40X5756 40X5852 40X5853 40X5854 40X5855 40X5857 40X5858 40X5859 40X5860 40X5861 40X5863 40X5903 40X5904 40X5906 40X5909 40X5910 40X5911 40X5937 40X5938 40X5939 40X5945 40X5946 40X5947 40X5952 40X5954 256MB user flash memory card
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4062-XXX 40X5955 40X5956 40X5957 40X5962 40X5969 40X5970 40X5971 40X5972 40X7001 40X7002 40X7003 40X7004 40X7007 40X7009 40X7010 40X7029 40X7030 40X7031 40X7032 40X7033 40X7034 40X7035 40X7036 40X7037 40X7038 40X7039 40X7040 40X7042 56P2129 56P2744 56P4191 56P4208 56P4210 56P4212 99A0954 99A1206 T650/T652 Forms and Bar code card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 T650/T652 Card for IPDS and SCS/TNe - - - - - - - - - - - - - - - - - - - - - -
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4062-XXX I-12 Service Manual
PAGE 585
Print defects guide Page 1 of 1 Print defects guide Match a set of repeating defects on a print job to the marks on one of the vertical lines. The line that best matches the defects on the print job indicates which particular part may be causing the defect. For example, the distance between these two marks represents a repeating defect that occurs every 28.3 mm (1.11 in.), which means the charge rollers may need to be replaced.
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