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Page 3: Table Of Contents
Table of contents Table of contents............iii Notices and safety information .
Page 4 Sensor (ADF media exit) static jam service check ........2-122 Sensor (ADF media exit) late jam service check .
Page 5 Diagnostic aids ............... . . Understanding the printer control panel .
Page 6 Printer theory ..............3-43 Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors ....3- 43 Model X658 paper path rolls and sensors .
Page 7 Pick arm assembly ............3-47 Switch (media size) .
Page 8 Media transport path ............3-78 Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors....3-78 Model X658 paper path rolls and sensors .
Page 9 240–245 paper jams ............3-87 250 paper jam .
Page 10 Switch (ADF closed interlock) removal ..........4-84 ADF unit assembly removal (models X651, X652/5535dn, X654, and X656) ....4-85 ADF unit assembly removal (model X658) .
Page 11 Laser cover removal (model X658) ..........4-104 Laser cover removal (models X651, X652/5535dn, X654, and X656) .....4-106 Standard output bin LED assembly removal (models X651, X652/5535dn, X654, and X656) .
Page 12 Sensor (scanner HP) assembly w/bracket removal ........4-154 LVPS cooling fan .
Page 13 MFP stapler assembly sensor (media stack) removal ....... . .4-215 MFP stapler assembly sensor (paddle HP) removal .
Page 14 Assembly 1: Covers (X651, X652/5535dn, X654, and X656) ....... . .
Page 15: Notices And Safety Information
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.
Page 16 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).
Page 17 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.
Page 18 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.
Page 19 Notices and safety information...
Page 20 Service Manual...
Page 21: Lithium Warning
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.
Page 22 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.
Page 23 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...
Page 24: Preface
Preface This manual contains maintenance procedures for service personnel. It is divided into the following chapters: General information contains a general description of the printer and the maintenance approach used to repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.
Page 25: General Information
1. General information The Dell™ 5535dn printer is an All-In-One laser multi-functional printer (MFP) that provides print, copy, scan, and fax functions designed to attach to most computer networks. The operator panel is touch-sensitive and allows the user to adjust the viewing angle.
Page 26: Printer Overview
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. Printer configuration Note: Printer configuration may vary depending on your printer model. Basic models Automatic Document Feeder (ADF) Printer control panel...
Page 27: Options
Options The following options are available. Some options are not available in every country or region. Contact your point of purchase for options available in your country or region. Available internal options • Memory cards – Printer memory – Flash memory –...
Page 28: Supported Paper Sizes, Types, And Weights
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 Optional Multipurpose...
Page 29: Paper Types And Weights Supported By The Printer
250-or 550-sheet Optional Multipurpose Paper size Dimensions trays (standard 2000-sheet Duplex unit feeder or optional tray Other Envelope 98 x 162 mm (3.9 x 6.4 in.) to 176 x 250 mm (6.9 x 9.8 in.) 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.
Page 30 The finisher supports 60-176 g/m2 (16-47 lb) paper weights. Optional hardware Output Expander (550 Standard exit bin StapleSmart II Paper type sheets) or High 5-Bin Mailbox (350 or 550 sheets) Finisher Capacity (500 sheets) (500 sheets) Output stacker (1850 sheets) Paper •...
Page 31: Tools Required For Service
Tools required for service Flat-blade screwdrivers, various sizes Phillips screwdrivers, various sizes 7/32 inch open-end wrench 7.0 mm nut driver 5.5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Analog or digital multimeter Flash light (optional) General information...
Page 32: Acronyms
Acronyms Automatic Document Feeder All-In-One Charge Coupled Device (CCD) Customer Replaceable Unit DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Electrophotographic process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte HCIT High-Capacity Input Tray HVPS High Voltage Power Supply Internal Tray Card LASER...
Page 33: Diagnostic Information
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.
Page 34: Confirm The Installation Status
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. •...
Page 35: User Attendance Messages
User attendance messages Error code or Error contents Description/Action Possible repair actions message System System Timeout The system detects a firmware Turn the power off; wait a few Timeout component that is no longer seconds, and then turn the responding. power back on.
Page 36 Error code or Error contents Description/Action Possible repair actions message Res Save Off This IR is displayed when the This message displays when Deficient Memory printer lacks sufficient memory the printer lacks sufficient to enable Resource Save. This memory to enable Resource message usually indicates the Save.
Page 37 Error code or Error contents Description/Action Possible repair actions message Insufficient Memory This message displays when The following actions may be the printer memory used to taken: restore the Print and Hold jobs from the disk and found that • Press to clear the some or all of the jobs could message.
Page 38 Error code or Error contents Description/Action Possible repair actions message 42.XY Cartridge Region This IR is displayed when the Install a new toner cartridge Mismatch printer detects that the installed that matches the correct cartridge has a region that regional specification. differs from the below options.
Page 39 Error code or Error contents Description/Action Possible repair actions message Std Network Software This error displays when a The following actions may be Error network port is detected, but taken: the printer cannot establish • Press to clear the communications with it. message and continue printing.
Page 40 Error code or Error contents Description/Action Possible repair actions message USB Port [x] Disabled Displayed when status is The following actions may be requested over the USB port, taken: but the port has been disabled. • Press to clear the Once the error has been displayed for the first time, message.
Page 41 Error code or Error contents Description/Action Possible repair actions message Incompatible An incompatible envelope 1. Turn off and unplug the Envelope Feeder feeder is installed. printer. 2. Remove the incompatible Remove the incompatible envelope feeder. feeder and press to clear 3.
Page 42 Error code or Error contents Description/Action Possible repair actions message Routine Maintenance The operator panel displays Scheduled maintenance Needed this message at each 300K required. page count interval. It is Refer to chapter 6. necessary to replace the fuser Go to “Preventive assembly, transfer roller, maintenance”...
Page 43: Error Code Table
Error code table Error code or Error contents Description/Action Possible repair actions message 200.00 Sensor (input) area The media is jammed in the 1. Fan the media and check for sensor (input) area. obstructions. 2. Go to sensor (input) service check.
Page 44: Service Checks
Error code or Error contents Description/Action Possible repair actions message 200.09 Printhead laser start The printhead laser start 1. Check all connections on failure process failed because it did the printhead. not receive proper feedback 2. Check all connections on signal from the printhead the main drive motor motor.
Page 45 Error code or Error contents Description/Action Possible repair actions message 200.15 Laser power did not Laser circuit failure on 1. Remove all media present settle printhead or system card in media path. assembly. 2. Check all connections on the printhead. 3.
Page 46 Error code or Error contents Description/Action Possible repair actions message 200.29 Sensor (input) The media reached the sensor Go to sensor (input) lingering lingering jam (input) but did not clear it within jam service check. the specified time. Source = Tray 2 See “Sensor (input) lingering Tray level = Empty jam service check”...
Page 47 Error code or Error contents Description/Action Possible repair actions message 200.48 Sensor (input) The media reached the sensor Go to sensor (input) lingering lingering jam (input) but did not clear it within jam service check. the specified time. Source = Tray 4 See “Sensor (input) lingering Tray level = Low jam service check”...
Page 48 Error code or Error contents Description/Action Possible repair actions message 201.06 Sensor (narrow The expected wide media is Go to sensor (narrow media) media) late jam late reaching the sensor late jam service check. (narrow media) within the Type 1 fuser See “Sensor (narrow media) specified time.
Page 49 Error code or Error contents Description/Action Possible repair actions message 201.31 Sensor (narrow The expected wide media is Go to sensor (narrow media) media) late jam late reaching the sensor late jam service check. (narrow media) within the Type 2 fuser See “Sensor (narrow media) specified time.
Page 50 Error code or Error contents Description/Action Possible repair actions message 201.56 Sensor (narrow The media is late reaching the Go to sensor (narrow media) media) late jam sensor (narrow media) within late jam service check. the specified time. Type 1 fuser See “Sensor (narrow media) late jam service check”...
Page 51 Error code or Error contents Description/Action Possible repair actions message 201.81 Sensor (narrow The media is late reaching the Go to sensor (narrow media) media) late jam sensor (narrow media) within late jam service check. the specified time. Type 2 fuser See “Sensor (narrow media) late jam service check”...
Page 52 Error code or Error contents Description/Action Possible repair actions message 202.07 Sensor (fuser output) Media reached the sensor Go to sensor (fuser output) lingering jam. (fuser output) but did not clear lingering jam service check. it in the specified time. Type 1 fuser See “Sensor (fuser output) lingering jam service check”...
Page 53 Error code or Error contents Description/Action Possible repair actions message 202.25 Paper jam around Page may be jammed in fuser 1. Remove all media present fuser exit or redrive exit or redrive area. in media path. area. 2. Check media for proper installation.
Page 54 Error code or Error contents Description/Action Possible repair actions message 202.34 Sensor (fuser output) Media reached the sensor Go to sensor (fuser output) lingering jam. (fuser output) but did not clear lingering jam service check. it in the specified time. Type 2 fuser See “Sensor (fuser output) lingering jam service check”...
Page 55 Error code or Error contents Description/Action Possible repair actions message 202.51 Sensor (fuser output) Media reached the sensor Go to sensor (fuser output) lingering jam. (fuser output) but did not clear lingering jam service check. it in the specified time. Destination is See “Sensor (fuser output) standard bin.
Page 56 Error code or Error contents Description/Action Possible repair actions message 202.61 Sensor (fuser output) Media reached the sensor Go to sensor (fuser output) lingering jam. (fuser output) but did not clear lingering jam service check. it in the specified time. Destination is See “Sensor (fuser output) standard bin.
Page 57 Error code or Error contents Description/Action Possible repair actions message 202.78 Sensor (narrow Media remains on the sensor 1. Go to sensor (fuser output) media) static jam (narrow media) during the static jam service check. warm up sequence. See “Sensor (fuser Type 2 fuser output) static jam service check”...
Page 58 Error code or Error contents Description/Action Possible repair actions message 202.87 Sensor (fuser output) Media reached the sensor Go to sensor (fuser output) lingering jam. (fuser output) but did not clear lingering jam service check. it in the specified time. Destination is output See “Sensor (fuser output) option.
Page 59 Error code or Error contents Description/Action Possible repair actions message 203.08 Redrive motor load The redrive motor assembly 1. Remove all media present error has failed or caused high in media path. mechanical load during the 2. Ensure that upper redive warm up sequence.
Page 60 Error code or Error contents Description/Action Possible repair actions message 230.00 Paper jam around Page may be jammed in 1. Remove all media present internal duplex. internal duplex area. in media path. 2. Check for obstructions in Source = Internal media path.
Page 61 Error code or Error contents Description/Action Possible repair actions message 230.08 Internal duplex drive The internal duplex drive motor 1. Remove all media present motor load error assembly has failed or caused in media path. high mechanical load during 2. Check all connections on Source = Internal warm up sequence.
Page 62 Error code or Error contents Description/Action Possible repair actions message 230.20 Internal duplex drive The internal duplex drive motor 1. Remove all media present motor lost encoder is not reporting pulses back to in media path. failure the engine. 2. Check all connections on the duplex media entrance Source = Internal drive motor assembly.
Page 63 Error code or Error contents Description/Action Possible repair actions message 234.00 Sensor (duplex exit) Media is late reaching the 1. Remove all media present late jam sensor (duplex exit) within the in media path. specified time. 2. Check media for proper Source = External installation.
Page 64 Error code or Error contents Description/Action Possible repair actions message 237.07 Paper jam around Page may be jammed in 1. Remove all media present external duplex external duplex area. in media path. 2. Check media for proper Source = External installation.
Page 65 Error code or Error contents Description/Action Possible repair actions message 238.04 Sensor (duplex Media remains on the sensor 1. Remove all media present double-feed) static (duplex double-feed) during the in media path. warm up sequence. 2. Replace the external duplex assembly if problem Source = External remains.
Page 66 Error code or Error contents Description/Action Possible repair actions message 239.01 External duplex Mechanical feed error or timing 1. Remove all media present assembly error error. in media path. 2. Check media for proper Source = External installation. duplex 3. Check for obstructions in media path.
Page 67 Error code or Error contents Description/Action Possible repair actions message 239.04 Input device ready Mechanical feed error or timing 1. Remove all media present response error. error. in media path. 2. Check media for proper Source = External installation. duplex 3.
Page 68 Error code or Error contents Description/Action Possible repair actions message 239.07 Select output device Mechanical feed error or timing 1. Remove all media present error. error. in media path. 2. Check media for proper Source = External installation. duplex 3. Check for obstructions in media path.
Page 69 Error code or Error contents Description/Action Possible repair actions message 241.01 Pick motor control The pick motor does not reach 1. Remove all media present failure. the proper operating speed at in media path. the specified time. 2. Ensure media tray is not Media tray 1 overfilled.
Page 70 Error code or Error contents Description/Action Possible repair actions message 241.08 Pick motor load error The pick motor has failed or 1. Remove all media present caused high mechanical load in media path. Source = Media tray 1 due to paper jam or bind. 2.
Page 71 Error code or Error contents Description/Action Possible repair actions message 241.18 Sensor (input) late The media is late reaching the Go to sensor (input) late jam sensor (input) within the service check. specified time. Source = Tray 1 See “Sensor (input) late jam service check”...
Page 72 Error code or Error contents Description/Action Possible repair actions message 242.05 Sensor (pass through) The media is late reaching the Go to sensor (pass through) late jam sensor (pass through) within late jam service check. the specified time. Source = Tray 2 See “Sensor (pass through) late jam service check”...
Page 73 Error code or Error contents Description/Action Possible repair actions message 242.52 Tray 2 pick motor The Pick motor encoder 1. Check all connections on overrun failure continues to detect pulses after the pick arm assembly. the motor was turned off. 2.
Page 74 Error code or Error contents Description/Action Possible repair actions message 242.49 HCIT tray lift motor The HCIT tray lift motor has 1. Ensure the HCIT media tray stalled failure stalled or has become assembly is properly inserted obstructed. into the machine. Source = Tray 2 2.
Page 75 Error code or Error contents Description/Action Possible repair actions message 242.65 Pick motor load error The pick motor has failed or 1. Remove all media present caused high mechanical load in media path. Source = Media tray 2 due to paper jam or bind. 2.
Page 76 Error code or Error contents Description/Action Possible repair actions message 242.68 Pick motor stop error Pick motor stop error detected 1. Remove all media present by options tray x in media path. Source = Media tray 2 2. Ensure media tray is not overfilled.
Page 77 Error code or Error contents Description/Action Possible repair actions message 243.05 Sensor (pass through) The media is late reaching the Go to sensor (pass through) late jam sensor (pass through) within late jam service check. the specified time. Source = Tray 3 See “Sensor (pass through) late jam service check”...
Page 78 Error code or Error contents Description/Action Possible repair actions message 243.34 Empty tray pick The pick arm attempted to pick 1. Check the media out attempted with no media in the tray. actuator for damage. 2. Replace the media out Source = Tray 3 actuator if problem remains.
Page 79 Error code or Error contents Description/Action Possible repair actions message 243.52 HCIT tray lift motor The HCIT tray lift motor 1. Ensure the HCIT media tray overrun failure continues to detect pulses after assembly is properly inserted the motor has turned off. into the machine.
Page 80 Error code or Error contents Description/Action Possible repair actions message 243.67 Pick motor overspeed The pick motor does not rotate 1. Remove all media present failure at the specified speed. in media path. 2. Ensure media tray is not Source = Media tray 3 overfilled.
Page 81 Error code or Error contents Description/Action Possible repair actions message 244.00 Media tray 4 area jam The media is jammed in the 1. Remove all media present media tray 4 area. in media path. 2. Check media for proper installation. 3.
Page 82 Error code or Error contents Description/Action Possible repair actions message 244.17 Media tray pulled jam A media tray above the source 1. Remove all media present tray was pulled during the in media path. printing process. 2. Close all media trays. 244.18 Pick retry timeout The engine timed out waiting...
Page 83 Error code or Error contents Description/Action Possible repair actions message 244.49 HCIT tray lift motor The HCIT tray lift motor has 1. Ensure the HCIT media tray stalled failure stalled or has become assembly is properly inserted obstructed. into the machine. Source = Tray 4 2.
Page 84 Error code or Error contents Description/Action Possible repair actions message 244.65 Pick motor load error The pick motor has failed or 1. Remove all media present caused high mechanical load in media path. Source = Media tray 4 due to paper jam or bind. 2.
Page 85 Error code or Error contents Description/Action Possible repair actions message 244.68 Pick motor stop error Pick motor stop error detected 1. Remove all media present by options tray x in media path. Source = Media tray 4 2. Ensure media tray is not overfilled.
Page 86 Error code or Error contents Description/Action Possible repair actions message 245.05 Sensor (pass through) The media is late reaching the Go to sensor (pass through) late jam sensor (pass through) within late jam service check. the specified time. Source = Tray 5 See “Sensor (pass through) late jam service check”...
Page 87 Error code or Error contents Description/Action Possible repair actions message 245.34 Empty tray pick The pick arm attempted to pick 1. Check the media out attempted with no media in the tray. actuator for damage. 2. Replace the media out Source = Tray 5 actuator if problem remains.
Page 88 Error code or Error contents Description/Action Possible repair actions message 245.52 HCIT tray lift motor The HCIT tray lift motor 1. Ensure the HCIT media tray overrun failure continues to detect pulses after assembly is properly inserted the motor has turned off. into the machine.
Page 89 Error code or Error contents Description/Action Possible repair actions message 245.67 Pick motor overspeed The pick motor does not rotate 1. Remove all media present failure at the specified speed. in media path. 2. Ensure media tray is not Source = Media tray 5 overfilled.
Page 90 Error code or Error contents Description/Action Possible repair actions message 250.03 Sensor (input) late The media is late reaching the Go to sensor (input) late jam sensor (input) within the service check. specified time. Source = MPF See “Sensor (input) late jam service check”...
Page 91 Error code or Error contents Description/Action Possible repair actions message 260.01 Envelope feeder Mechanical feed error or timing 1. Remove the envelope assembly error error. feeder. 2. Remove all media present in media path. 3. Check media for proper installation. 4.
Page 92 Error code or Error contents Description/Action Possible repair actions message 260.06 Sensor (envelope The media is late reaching the 1. Remove the envelope feeder pass through) sensor (envelope feeder pass feeder. late jam through) within the specified 2. Remove all media present time.
Page 93 Error code or Error contents Description/Action Possible repair actions message 260.15 Sensor (input) late The media is late reaching the Go to sensor (input) late jam sensor (input) within the service check. specified time. Source = Envelope See “Sensor (input) late jam feeder service check”...
Page 94 Error code or Error contents Description/Action Possible repair actions message 27x.15 Sensor (output pass Media remains on the sensor See “Sensor (output pass through) static jam (output pass through) during through) static jam service x = bin the warm up sequence. check”...
Page 95 Error code or Error contents Description/Action Possible repair actions message 27x.51 Right tamper does not The sensor (right tamper HP) 1. Check all the connections on leave home position does not detect that the tamper the output option controller x = bin failure has moved from home position.
Page 96 Error code or Error contents Description/Action Possible repair actions message 28x.26 Timer 0 overflow (1ms A software failure has occurred 1. Turn the machine off/on. timer did not get with the output option. x = bin 2. Replace the output option if serviced for an entire number problem remains.
Page 97 Error code or Error contents Description/Action Possible repair actions message 28x.35 Sensor (self priming) The sensor (self priming) within 1. Check all the connections on late failure the stapler assembly does not the output option controller x = bin detect a ready staple in the card and the stapler assembly.
Page 98 Error code or Error contents Description/Action Possible repair actions message 28x.38 Staple ready home The sensor (self priming) within 1. Check all the connections on position jam the stapler assembly does not the controller card and the x = bin detect a ready staple in the stapler assembly.
Page 99 Error code or Error contents Description/Action Possible repair actions message 28x.40 Left tamper does not The sensor (left tamper HP) 1. Check all the connections on leave home position does not detect that the tamper the output option controller x = bin failure has moved from home position.
Page 100 Error code or Error contents Description/Action Possible repair actions message 28x.42 Right tamper does not The sensor (right tamper HP) 1. Check all the connections on leave home position does not detect that the tamper the output option controller x = bin failure has moved from home position.
Page 101 Error code or Error contents Description/Action Possible repair actions message 28x.46 Paddle home position The sensor (paddle HP) does 1. Check all the connections on not detect that the paddle is the output option controller x = bin operating. card. number Applies to: 2.
Page 102 Error code or Error contents Description/Action Possible repair actions message 28x.50 Left tamper home The left tamper home position 1. Check all the connections on position jam is not detected by the sensor the output option controller x = bin (left tamper HP) card.
Page 103 Error code or Error contents Description/Action Possible repair actions message 28x.54 Eject motor encoder The eject motor encoder 1. Check all the connections on not detected detection is lost during normal the output option controller x = bin operation. card. number Applies to: 2.
Page 104 Error code or Error contents Description/Action Possible repair actions message 28x.61 DMID command is not A software failure has occurred 1. Turn the machine off/on. received for 500ms with the output option. x = bin 2. Replace the output option if after main motor runs number problem remains.
Page 105 Error code or Error contents Description/Action Possible repair actions message 28x.68 Staple ready home The sensor (self priming) within 1. Check all the connections on position jam the stapler assembly does not the controller card and the x = bin detect a ready staple prior to a stapler assembly.
Page 106 Error code or Error contents Description/Action Possible repair actions message 28x.70 Stapler mechanism The sensor (home signal) 1. Check all the connections on not in home position within the stapler assembly the controller card and the x = bin failure detected that the stapler stapler assembly.
Page 107 ADF controller card assembly. 2. Replace the scanner controller card assembly if problem remains. Go to “Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-132 or “Scanner controller card assembly removal (model X658)” on page 4-129. 2-75...
Page 108 Error code or Error contents Description/Action Possible repair actions message 842.xx ADF communication The ADF controller card has 1. Check all connections on the failure lost communication with the ADF controller card assembly. system. 2. Replace the ADF controller card assembly if problem remains.
Page 109 Error code or Error contents Description/Action Possible repair actions message 902.xx System software error Code detected unusual event 1. POR the machine and print or timing. a simple test page to determine if the problem is system software related, or if the customer is sending a corrupted print job.
Page 110 Error code or Error contents Description/Action Possible repair actions message 906.xx RIP interface driver Code detected unusual event 1. POR the machine and print error or timing. a simple test page to determine if the problem is system software related, or if the customer is sending a corrupted print job.
Page 111 Error code or Error contents Description/Action Possible repair actions message 914.00 Pick arm motor no The pick arm motor encoder 1. Check all the connections on encoder not detected detection is lost during normal the pick arm assembly. failure operation 2.
Page 112 Error code or Error contents Description/Action Possible repair actions message 916.01 Internal duplex drive The duplex drive motor does 1. Check all the connections on motor over speed not rotate at the specified the duplex drive motor failure speed. assembly. 2.
Page 113 Error code or Error contents Description/Action Possible repair actions message 920.04 Fuser warm-up failure The fuser hot roll is too cool 1. Turn the machine off/on when heating to desired and ensure the fuser unit Fuser type = 1 temperature after slope change assembly is properly within standby control only.
Page 114 Error code or Error contents Description/Action Possible repair actions message 920.25 Fuser under Fuser does not maintain proper 1. Turn the machine off/on temperature operating temperature within and ensure the fuser unit steady state control. assembly is properly Fuser type = 2 installed.
Page 115 Error code or Error contents Description/Action Possible repair actions message 920.31 Fuser warm-up failure The fuser hot roll temperature 1. Turn the machine off/on does not increase while the and ensure the fuser unit Fuser type = 2 lamp is turned on. assembly is properly installed.
Page 116 Error code or Error contents Description/Action Possible repair actions message 920.53 Fuser warm-up failure The fuser hot roll is too cool Replace the fuser unit while checking for slope assembly if problem remains. Fuser type = 1 change in standby. Go to “Fuser unit assembly removal”...
Page 117 Error code or Error contents Description/Action Possible repair actions message 920.82 Fuser warm-up failure The fuser hot roll temperature Replace the fuser unit is not maintained properly assembly if problem remains. Fuser type = 2 while the media in the fuser Go to “Fuser unit assembly nip.
Page 118 Error code or Error contents Description/Action Possible repair actions message 922.04 Fuser warm-up failure The fuser hot roll has timed out 1. Turn the machine off/on and not reached “final lamp and ensure the fuser unit Fuser type = 1 detection”...
Page 119 Error code or Error contents Description/Action Possible repair actions message 922.07 Fuser warm-up failure The fuser hot roll does not 1. Turn the machine off/on reach operating temperature and ensure the fuser unit Fuser type = 1 after increasing interpage gap. assembly is properly installed.
Page 120 Error code or Error contents Description/Action Possible repair actions message 922.28 Fuser warm-up failure The fuser hot roll does reach 1. Turn the machine off/on the “final lamp detection” and ensure the fuser unit Fuser type = 2 parameter but not in the assembly is properly specified time.
Page 121 Error code or Error contents Description/Action Possible repair actions message 922.31 Fuser warm-up failure The fuser hot roll did not reach 1. Turn the machine off/on operating temperature within and ensure the fuser unit Fuser type = 2 new enhanced control. assembly is properly installed.
Page 122 Error code or Error contents Description/Action Possible repair actions message 922.54 Fuser warm-up failure The fuser hot roll has timed out Replace the fuser unit and not reached “final lamp assembly if problem remains. Fuser type = 1 detection” during the specified Go to “Fuser unit assembly time.
Page 123 Error code or Error contents Description/Action Possible repair actions message 923.00 Fuser over The fuser hot roll has 1. Turn the machine off/on temperature failure. exceeded the proper operating and ensure the fuser unit temperature. assembly is properly Fuser type = 1 installed.
Page 124 Error code or Error contents Description/Action Possible repair actions message 923.75 Fuser over The fuser hot roll has Replace the fuser unit temperature failure. exceeded the proper operating assembly if problem remains. temperature. Go to “Fuser unit assembly Fuser type = 2 removal”...
Page 125 Error code or Error contents Description/Action Possible repair actions message 925.00 Incorrect fuser or The machine detected a 115 V 1. Turn the machine off/on fuser lamp detected. lamp in a 220 V machine. The and ensure the fuser unit fuser lamp has an excessive assembly is properly Fuser type = 1...
Page 126 Error code or Error contents Description/Action Possible repair actions message 925.27 Incorrect fuser or The machine detected a 115 V 1. Turn the machine off/on fuser lamp detected. lamp in a 220 V machine. The and ensure the fuser unit fuser lamp has an excessive assembly is properly Fuser type = 2...
Page 127 Error code or Error contents Description/Action Possible repair actions message 925.76 Incorrect fuser or The machine detected a 115 V 1. Turn the machine off/on fuser lamp detected. lamp in a 220 V machine. The and ensure the fuser unit fuser lamp has an excessive assembly is properly Fuser type = 2...
Page 128 Error code or Error contents Description/Action Possible repair actions message 927.05 Main cooling fan over The main cooling fan does not 1. Check for cooling fan speed failure. reach the specified speed. obstructions. 2. Check the connections on the main cooling fan. 3.
Page 129 Error code or Error contents Description/Action Possible repair actions message 927.16 Print cartridge cooling The Print cartridge cooling fan 1. Check for cooling fan fan over speed failure. does not reach the specified obstructions. speed. 2. Check the connections on the main cooling fan.
Page 130 Error code or Error contents Description/Action Possible repair actions message 931.00 No first laser H sync The hsync signal is missing or Replace the printhead not at the correct voltage. assembly. Go to “Printhead assembly removal” on page 4-34. 932.00 Printhead lost laser H The hsync signal is missing or Replace the printhead...
Page 131 Error code or Error contents Description/Action Possible repair actions message 936.20 Main drive motor The main drive motor assembly 1. Check all connections on assembly failure may be faulty or has failed. the system card assembly. 2. Check all connections on Failed to stop within the main drive motor timeout.
Page 132 Error code or Error contents Description/Action Possible repair actions message 936.60 Main drive motor The main drive motor assembly 1. Check all connections on assembly failure may be faulty or has failed. the system card assembly. 2. Check all connections on No lock detected at the main drive motor normal motor start.
Page 133 Error code or Error contents Description/Action Possible repair actions message 937.40 Main drive motor The main drive motor assembly 1. Check all connections on assembly failure may be faulty or has failed. the system card assembly. 2. Check all connections on Over speed detected the main drive motor during speed control.
Page 134 Error code or Error contents Description/Action Possible repair actions message 937.70 Main drive motor The main drive motor assembly 1. Check all connections on assembly failure may be faulty or has failed. the system card assembly. 2. Check all connections on Loss of lock detected the main drive motor by higher-level code.
Page 135 2. If the problem remains, replace the scanner controller card. Go to “Scanner controller card assembly removal (model X658)” on page 4-129 or “Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656)" on page 4-132. 2-103 Diagnostic information...
Page 136 Error code or Error contents Description/Action Possible repair actions message 950.xx NVRAM mismatch Mismatch between system Warning: When replacing any failure card EEPROM and operator of the following components: panel mirror. • Scanner interface card ".xx" codes: assembly. • System card assembly 00-29: mismatch between Only replace one component at system and mirror...
Page 137 Error code or Error contents Description/Action Possible repair actions message 956.01 System card The system card processor is Replace the system card processor over over temperature or is assembly. temperature damaged. Go to “System card assembly removal” on page 4-50. 957.xx The ASIC has failed on the Replace the system card...
Page 138 Error code or Error contents Description/Action Possible repair actions message 982.04 Output option An output option was not fully 1. Turn the main power off. communication seated onto the printer or has 2. Remove and reinstall the failure. been removed while the main output option.
Page 139: Sensor (Input) Service Check
Service checks Sensor (input) service check Step Check Check the sensor (input) for damage. Go to step 2. Replace the sensor (input). Is the above component free from damage? Go to “Sensor (input) removal” on page 4-42. 1. Enter the diagnostic mode The sensor is Go to step 2.
Page 140: Sensor (Narrow Media) Service Check
Sensor (narrow media) service check Step Check Check the sensor (narrow media) for damage. Go to step 2. Replace the fuser unit assembly. Is the above component free from damage? Go to “Fuser unit assembly removal” on page 4-15. 1. Enter the diagnostic mode The sensor is Go to step 2.
Page 141: Sensor (Duplex Input) Service Check (External Duplex Only)
Sensor (duplex input) service check (external duplex only) Step Check Check the sensor (duplex input) for damage. Go to step 2. Replace the external duplex Is the above component free from damage? unit assembly. 1. Enter the diagnostic mode The sensor is Go to step 2.
Page 142: Sensor (Envelope Feeder Empty) Service Check
Step Check Check the above sensor for proper connection. Replace the Replace the sensor (pass connection. Is the above sensor connected properly? through). Go to “Sensor (pass through) with cable removal” on page 4-198. Sensor (envelope feeder empty) service check Step Check 1.
Page 143: Switch (Adf Closed Interlock) Jam Service Check
Switch (ADF closed interlock) jam service check Step Check 1. Enter the diagnostic mode The sensor is Go to step 2. working properly 2. Select Scanner tests 3. Select Sensor tests 4. Observe the line item “sensor (ADF closed interlock)” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
Page 144: Sensor (Adf Sheet Through) Static Jam Service Check
Sensor (ADF sheet through) static jam service check Use this procedure for the following jams: • 290.00 Check the media path. Go to step 2. Remove any media or media Is the media path free of media or media fragments? fragments.
Page 145: Sensor (Adf Sheet Through) Late Jam Service Check 290.01
Sensor (ADF sheet through) late jam service check 290.01 Use this procedure for the following jams: • 290.01 Step Check Check the original document condition. Go to step 2. Remove damaged original Is the original document free of paper clips and staples as document and well as damage such as creases, tears, holes or excessive replace with a...
Page 146: Sensor (Adf 1St Scan) Late Jam Service Check
Step Check Check the sensor (ADF sheet through) for proper Replace the Replace the connection. sensor (ADF connection. sheet through). Is the above component properly connected? Go to “Sensor (ADF sheet through) removal” on page 4-82. Place an undamaged document in the ADF, and perform a Replace the ADF Problem solved.
Page 147: Sensor (Adf Sheet Through) Lingering Jam Service Check
Step Check Check the sensor (ADF 1st scan) for proper operation. Go to step 6. Go to step 5. 1. Enter the Diagnostics Menu. 2. Touch SCANNER TESTS. 3. Touch Sensor Tests. 4. Observe the line “sensor (ADF 1st scan)” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked?
Page 148 Step Check Check the original document condition. Go to step 3. Remove damaged original document Is the original document free of paper clips and staples as and replace with a well as damage such as creases, tears, holes or excessive new undamaged wear? original document.
Page 149: Sensor (1St Scan) Static Jam Service Check
Sensor (1st scan) static jam service check Use this procedure for the following jams: • 290.10 Check the media path. Go to step 2. Remove any media or media Is the media path free of media or media fragments? fragments. Check the sensor (ADF 1st scan) for proper operation.
Page 150: Sensor (2Nd Scan) Static Jam Service Check
Sensor (2nd scan) static jam service check Use this procedure for the following jams: • 291.00 Check the media path. Go to step 2. Remove any media or media Is the media path free of media or media fragments? fragments. Check the sensor (2nd scan) for proper operation.
Page 151: Sensor (Adf Media Exit) Late Jam Service Check
Step Check Check the original document condition. Go to step 3. Remove damaged original document Is the original document free of paper clips and staples as and replace with a well as damage such as creases, tears, holes or excessive new undamaged wear? original document.
Page 152 Step Check Check the original document condition. Go to step 2. Remove damaged original document Is the original document free of paper clips and staples as and replace with a well as damage such as creases, tears, holes or excessive new undamaged wear? original document.
Page 153: Adf Top Door Open Jam Service Check
ADF top door open jam service check Use this procedure for the following jams: • 292.00 Step Check Remove all documents from the ADF. Go to step 2. Problem solved Place an undamaged document in the ADF, and perform a ADF test.
Page 154: Sensor (Adf Media Exit) Static Jam Service Check
Step Check Check the sensor (ADF document set) for proper operation. Go to step 6. Go to step 5. 1. Enter the Diagnostics Menu. 2. Touch SCANNER TESTS. 3. Touch Sensor Tests. 4. Touch TBD Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked? Check the sensor (2nd scan) for proper connection.
Page 155 Check the sensor (ADF media exit) for proper connection. Replace the Replace the sensor (ADF connection. Is the above component properly connected? media exit). Go to “Sensor (standard bin exit) actuator assembly removal” on page 4-89 or “Sensor (ADF media exit) bracket assembly removal (X651)”...
Page 156 Step Check Check the media path for contaminates. Go to step 4. Remove all contaminates from Is the media path free of excess media dust and foreign the media path. objects such as paper clips and staples? Check the sensor (ADF media exit) for proper operation. Go to step 6.
Page 157: Sensor (Adf Media Exit) Lingering Jam Service Check
Sensor (ADF media exit) lingering jam service check Use this procedure for the following jams: • 294.03 Step Check Check the original document condition. Go to step 2. Remove damaged original document Is the original document free of paper clips and staples as and replace with a well as damage such as creases, tears, holes or excessive new undamaged...
Page 158 Step Check Check the ADF transport drive motor assembly for proper Replace the ADF Replace the connection. transport drive connection. motor assembly. Is the above component properly connected? Go to “ADF transport drive motor bracket assembly w/ cable removal” on page 4-77. Place an undamaged document in the ADF, and perform a Replace the ADF Problem solved.
Page 159: Sensor (Input) Late Jam Service Check
Sensor (input) late jam service check Use this procedure for the following jams: • 200.07 • 230.04 • 230.06 • 237.00 • 239.11 • 241.06 • 214.10 • 241.11 • 241.12 • 241.14 • 241.15 • 241.16 • 241.18 • 242.09 •...
Page 160 Step Check Check the sensor (duplex input) for proper operation. Go to step 12. Go to step 11. 1. Enter the diagnostic mode 2. Select Duplex tests 3. Select sensor test 4. Observe the line item “input” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
Page 161: Sensor (Input) Lingering Jam Service Check
Step Check Check the sensor (input) for proper operation. The sensor is Go to step 19. working properly. 1. Enter the diagnostic mode Go to step 20. 2. Select Base sensor test 3. Observe the line item “input” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
Page 162: Sensor (Input) Early Jam Service Check
Step Check Check the sensor (input) for proper operation. Go to step 6. Go to step 5. 1. Enter the diagnostic mode 2. Select Base sensor test 3. Observe the line item “input” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
Page 163: Sensor (Input) Static Jam Service Check
Step Check Check media origination. Go to step 2. Go to step 5. Did the media originate from the MPF? Check the MPF pick roll assembly. Go to step 3. Clean or replace the MPF pick roll Is the above component free of excess wear and assembly.
Page 164: Sensor (Fuser Output) Late Jam Service Check
Step Check Check the media path for partially fed or jammed media. Go to step 2. Remove any pre- staged or jammed Is the media path free from partially fed or jammed media? media. Check the sensor (input) for proper operation. Go to step 4.
Page 165: Sensor (Fuser Output) Lingering Jam Service Check
Step Check Check the above sensor for proper connection. Replace the fuser Replace the unit assembly. connection. Is the above sensor connected properly? Go to “Fuser unit assembly removal” on page 4-15. Check the aligner assembly for obstructions. Go to step 8. Remove obstructions.
Page 166 Step Check Check the fuser unit assembly for damage and life Replace the fuser Go to step 5. expiration. unit assembly. Is the above component damaged or has it exceeded life? Go to “Fuser unit assembly removal” on page 4-15. Check the sensor (fuser output) for proper operation.
Page 167: Sensor (Fuser Output) Static Jam Service Check
Sensor (fuser output) static jam service check Use this procedure for the following jams: • 202.06 • 202.13 • 202.31 • 202.38 • 202.56 • 202.63 • 202.81 • 202.88 Step Check Check the media path for partially fed or jammed media. Go to step 2.
Page 168: Sensor (Narrow Media) Static Jam Service Check
Step Check Check the sensor (narrow media) for proper operation. Go to step 7. Go to step 6. 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.
Page 169: Sensor (Duplex Input) Late Jam Service Check
Check Check the sensor (narrow media) for proper operation. Go to step 4. Go to step 3. 1. Enter the diagnostic mode 2. Select Base sensor test 3. Observe the line item “input” Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or blocked.
Page 170 Step Check Perform a print test and check the duplex drive motor Go to step 8 Replace the assembly for proper operation. duplex drive motor assembly. Does the above component operate properly? Go to “Duplex drive motor assembly removal” on page 4-9.
Page 171: Sensor (Duplex Input) Lingering Jam Service Check
Sensor (duplex input) lingering jam service check Use this procedure for the following jams: • 230.01 • 230.05 • 232.00 Step Check Check media origination. Go to step 2 Go to step 7 Did the media originate from the internal duplex? Check the internal duplex media path for obstructions.
Page 172: Sensor (Duplex Input) Static Jam Service Check
Step Check Perform a print test using the duplex. Contact next Problem solved. highest level of Does the problem remain? tech support. Sensor (duplex input) static jam service check Use this procedure for the following jams: • 230.13 • 238.01 •...
Page 173: Sensor (Pass Through) Late Jam Service Check
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 •...
Page 174: Sensor (Pass Through) Lingering Jam Service Check
Step Check Perform a print test and check the pick arm assembly for Go to step 8. Replace the the appropriate media tray. appropriate pick arm assembly. Is the media properly picked and advanced out of the appropriate media tray? Go to “Pick arm assembly removal”...
Page 175: Sensor (Pass Through) Static Jam Service Check
Step Check Check the above sensor for proper connection. Replace the Replace the appropriate connection. Is the above sensor connected properly? Sensor (pass through). Go to “Sensor (pass through) with cable removal” on page 4-198. Perform a print test and check the main motor assembly. Replace the main Replace the drive motor...
Page 176: Sensor (Stapler Pass Through) Late Jam Service Check
Sensor (stapler pass through) late jam service check Step Check Check the output option for proper installation. Go to step 2. Remove then reinstall the output Is the above component properly installed? option Check for obstructions in the media path between the base Go to step 3.
Page 177: Sensor (Stapler Pass Through) Static Jam Service Check
Sensor (stapler pass through) static jam service check Step Check Check the media path for partially fed or jammed media. Go to step 2. Remove any pre- staged or jammed Is the media path free from partially fed or jammed media? media.
Page 178: Sensor (Output Pass Through) Lingering Jam Service Check
Sensor (output pass through) lingering jam service check Step Check Check the output option for proper installation. Go to step 2. Remove then reinstall the output Is the above component properly installed? option Check for obstructions in the media path between the Go to step 3.
Page 179: Sensor (Mailbox Empty) Late Jam Service Check
Check Check the above sensor for proper connection. Replace the Replace the sensor (output connection. Is the above sensor connected properly? pass through). Go to “4-bin mailbox assembly sensor (pass through) removal” on page 4-232. Perform a print test using the output option. Replace the output Problem solved.
Page 180: Sensor (Mailbox Empty) Static Jam Service Check
Step Check Check for obstructions in the media path between the Go to step 3. Remove Sensor (mailbox empty) machine and the media bin. obstructions. Is the media path free from obstructions? Check the sensor (mailbox empty) for proper operation. Go to step 5.
Page 181: Sensor (Scanner Hp) Service Check
Sensor (toner empty) service check Step Check Check the sensor (toner empty) for proper installation. go to step 2. Reinstall the sensor (toner Is the above component properly installed? empty) Check the sensor (toner empty) for proper operation. The sensor is Go to step 3.
Page 182: Nvram Mismatch Failure (950.00 Through 950.29) Service Check
Check the sensor (ADF 2nd scan) for proper installation. Go to step 2. Reinstall the sensor (ADF 2nd Is the above component properly installed? scan) Check the sensor (ADF 2nd scan) for proper operation. The sensor is Go to step 3. working properly.
Page 183: Image Quality Trouble
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 2-152. •...
Page 184: Image Quality
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 Check Check the media condition. Problem solved. Go to step 2. Load new, dry, recommended media, and perform a print test.
Page 185 Step Check Check the printhead assembly for proper connection. Replace the Replace the printhead connections. Is the above component properly connected? assembly. Go to “Printhead assembly removal” on page 4-34. Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support.
Page 186: Blank Print (No Print)
Blank print (no print) Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the media condition. Problem solved. Go to step 2. Load new, dry, recommended media, and perform a print test. Is the image density normal? Check the toner level.
Page 187 Step Check Check the laser beam route. Go to step 8. Remove debris or clean the Check for debris between the printhead assembly and printhead the PC drum. assembly window. Is the laser beam route free of debris and the glass window, in the printhead assembly, free of contamination? Check the HVPS card assembly for proper connection.
Page 188: Solid Black
Solid black Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Check the charge roll assembly for proper installation. Go to step 2. Replace the charge roll Is the above component properly installed? assembly.
Page 189: Vertical Lines And Bands (Process Direction)
Vertical lines and bands (process direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Is the media transfer route and the media path clear of Go to step 3.
Page 190: Horizontal White Stripes Or Bands (Side To Side Direction)
Horizontal white stripes or bands (side to side direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
Page 191: Vertical Stripes (Process Direction)
Vertical stripes (process direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Are the media transfer route and the media path free of Go to step 3.
Page 192: Horizontal Stripes (Side To Side Direction)
Step Check Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support. Horizontal stripes (side to side direction) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media.
Page 193 Step Check Check the heat roll and pressure roll. Replace the Go to step 7. fuser unit Remove the fuser unit assembly. assembly. CAUTION: : Allow Go to “Fuser the fuser unit unit assembly assembly to cool removal” on page 4-15. down.
Page 194: Partial Lack
Partial lack Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Check the toner level. Go to step 3. Replace the print cartridge.
Page 195 Spots Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media route free of contamination or debris? contamination.
Page 196 Step Check Check the printhead installation. Go to step 8. Reinstall and adjust the Is the above component properly installed? printhead assembly. Go to “Printhead assembly removal” on page 4-34. Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support.
Page 197: After Image
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 Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media.
Page 198: Background (Fog)
Background (fog) Leading edge Trailing edge Step Check Check the media condition. Go to step 2. Problem solved. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Check the media transfer route. Go to step 3. Remove debris Is the media path free of contamination or debris.
Page 199 Skew Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for damaged printer caster. Is the setup surface normal? Properly load media into the media tray assembly and Go to step 3.
Page 200: Media Damage
Media damage Leading edge Trailing edge Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for missing printer foot. Is the setup surface normal? Check the media feed. Go to step 3.
Page 201 Step Check Check the heat roll and pressure roll. Replace the Inspect the fuser unit machine for Remove the fuser unit assembly. assembly. obstructions in the media path. CAUTION: : Allow Go to “Fuser the fuser unit unit assembly assembly to cool removal”...
Page 202: No Fuse
No fuse Leading edge Trailing edge Step Check Check the fuser unit assembly installation. Go to step 2. Reinstall the fuser unit Is the fuser unit assembly properly installed? assembly. Check the media condition. Go to step 3. Problem solved. Load new, dry, recommended media.
Page 203: Adf & Scanner Related Troubleshooting
ADF & Scanner 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: • Dark print — “Faint print (Low contrast)” on page 2-152. • Vertical stripes— “Vertical stripes (process direction)” on page 2-159. •...
Page 204: Adf & Scanner Image Quality
Perform a print test using the ADF & scanner unit Replace the Problem solved. assemblies. scanner controller card Does the error continue? assembly. Go to “Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-132. 2-172 Service Manual...
Page 205: Vertical Lines (Process Direction Using The Adf)
Is the white strip contaminated? Perform a print test using the scanner unit assembly. Replace the Problem solved. scanner unit Does the error continue? assembly. Go to “Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-94. 2-173 Diagnostic information...
Page 206: Spots (Using Flatbed Scanner)
Problem solved. scanner Does the error continue? controller card assembly. Go to “Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-132. Spots (using flatbed scanner) Leading edge Leading edge Trailing edge Trailing edge Step Check...
Page 207 Perform a print test using the flatbed scanner assembly. Replace the Problem solved. scanner Does the error continue? controller card assembly. Go to “Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-132. 2-175 Diagnostic information...
Page 208: Skew (Using Adf)
Skew (using ADF) Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement. Go to step 2. Correct the installation Check the installation surface for irregularities. placement. Check for damaged printer caster. Is the setup surface normal? Properly load document into the ADF unit assembly and Go to step 3.
Page 209: Media Damage (Using Adf)
Media damage (using ADF) Leading edge Trailing edge Step Check Properly load document into the ADF unit assembly and Go to step 2. Problem solved. ensure all guides are set correctly. Re-print the defective image. Does the error continue? Check for obstructions in the area of the media feed Go to step 3.
Page 210: Network Service Check
Network service check Note: Before starting this service check, print out the network setup page. This page is found under Menu - Reports - Network Settings. Consult the network administrator to verify that the physical and wireless network settings displayed on the network settings page for the device are properly configured. If a wireless network is used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic interference.
Page 211 Step Questions / actions Try using a different ethernet cable. Problem resolved Go to step 14. Did this remedy the situation? Have the network administrator check the Replace the controller Contact the network network drop for activity. board. Go to “System card administrator.
Page 212 2-180 Service Manual...
Page 213: Diagnostic Aids
3. Diagnostic aids Understanding the printer control panel PQRS WXYZ Item Description Display View scanning, copying, faxing, and printing options as well as status and error messages. Keypad Enter numbers or symbols on the display. PQRS WXYZ Dial Pause • Press to cause a two- or three-second dial pause in a fax number.
Page 214: Understanding The Home Screen
Item Description Home Press to return to the home screen. Start • Press to initiate the current job indicated on the display. • From the home screen, press to start a copy job with the default settings. • If pressed while a job is scanning, the button has no effect. Indicator light Indicates the printer status: •...
Page 215 Display item Description Opens the File Transfer Protocol (FTP) menus Note: This function must be set up by your system support person. Once it is set up, it appears as a display item. Status message bar • Shows the current printer status such as Ready or Busy. •...
Page 216: Using The Touch-Screen Buttons
Using the touch-screen buttons Note: Depending on your options and administrative setup, your screens and buttons may vary from those shown. Sample touch screen Button Function Home Returns to the home screen Scroll down Opens a drop-down list Left scroll decrease Scrolls to another value in decreasing order Right scroll increase Scrolls to another value in increasing order...
Page 217: Other Touch-Screen Buttons
Button Function Right arrow Scrolls right Submit Saves a value as the new user default setting Submit Back Navigates back to the previous screen Other touch-screen buttons Button Function Down arrow Moves down to the next screen Up arrow Moves up to the next screen Unselected radio button This is an unselected radio button.
Page 218 Button Function Cancel Jobs Opens the Cancel Jobs screen. The Cancel Jobs screen shows three headings: Print, Fax, and Network. The following items are available under the Print, Fax, and Network headings: • Print job • Copy job • Fax profile •...
Page 219: Accessing Service Menus
Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Menu 1. Turn off the printer. The Diagnostics Menu group consists of menus, settings, and operations that are used to diagnose 2.
Page 220: Diagnostics Menu
Diagnostics Menu Entering Diagnostics Menu 1. Turn off the printer. 2. Press and hold 3 and 6 buttons simultaneously. 3. Turn on the printer. 4. 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.
Page 221 Diagnostics Menu tests (Continued) DUPLEX TESTS (if installed) Quick Test See “Quick Test (duplex)” on page 3-16 Top Margin See “Top Margin (duplex)” on page 3-17 Sensor Test See “Sensor Test (duplex)” on page 3-17 Motor Test See “Motor Test (duplex)” on page 3-17 Duplex Feed 1 See “Duplex Feed 1”...
Page 222 Diagnostics Menu tests (Continued) PRINTER SETUP Defaults See “Defaults” on page 3-22 Printed Page Count See “Printed Page Count” on page 3-22 Perm Page Count See “Permanent Page Count” on page 3-22 Serial Number See “Serial Number” on page 3-22 Envelope Enhance See “Engine Settings 1 through 16”...
Page 223: Registration (Printer)
Registration (printer) Print registration makes sure the printing is properly aligned on the page. REGISTRATION Top Margin Bottom Margin Left Margin Right Margin Quick Test Submit Back The settings available are: Description Value Direction of change Top Margin -25 to +25 A positive change moves the image down the page and increases the top margin.
Page 224: Print Tests
To set print registration: 1. Print the Quick Test page. Touch REGISTRATION from the Diagnostics Menu. b. Touch to select Quick Test. You may need to scroll to the next page. Retain this page to determine the changes you need to make to the margins settings. The diamonds in the margins should touch the margins of the page.
Page 225: Input Source 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.
Page 226: Hardware Tests
The following is included in the DIAGNOSTICS version of the print quality pages: • Values from EP SETUP in DIAGNOSTICS, including: Fuser temperature, warm-up time, transfer, print contrast, charge roll settings and gap adjust. • Contents of the EVENT LOG from DIAGNOSTICS. •...
Page 227: Dram Test
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.
Page 228: Duplex Tests
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 USB High Speed...
Page 229: Top Margin (Duplex)
Top Margin (duplex) This setting controls the offset between the first scan line on the front of the duplex page and the first scan line on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex top margin.
Page 230: Duplex Feed
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. To run the Duplex Feed 1 Test: 1.
Page 231: Input Tray Tests
INPUT TRAY TESTS 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.
Page 232: Output Bin Tests
OUTPUT BIN TESTS Feed Tests (output bins) Use these tests to verify that media can be fed to the standard 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.
Page 233: Device Tests
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.
Page 234: Printer Setup
PRINTER SETUP PRINTER SETUP Defaults Printed Page Count Permanent Page Count Serial Number xxxxxxx Engine Setting 1 Engine Setting 2 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.
Page 235: Configuration Id
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.
Page 236: Ep Setup
EP SETUP EP SETUP EP Defaults Fuser Temp Normal Fuser Page Count Warm Up Time Transfer Medium Print Contrast Medium 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.
Page 237: Event Log
Transfer The transfer can be adjusted to Low, Medium, or High. The default setting is Medium. Touch Back to return to Diagnostics Menu. 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. Touch Back to return to Diagnostics Menu.
Page 238: Print Log
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 239: Scanner Tests
SCANNER TESTS Back Side Scan Uniformity This procedure should be run after the ADF has been replaced. Before proceeding, make sure that the scanner glass and backing material are clean. ASIC Test A pattern appears and ASIC Test Passed displays. If xxxxxx displays, the test was unsuccessful. Press Stop to return to the SCANNER TESTS menu.
Page 240: Entering Configuration Menu
Configuration menu (CONFIG MENU) Entering Configuration Menu 1. Turn off the printer. 2. Press and hold 2 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available menus Note: Some menus are not available, depending on the configuration of the printer. Maintenance Counter Value See “Maintenance Counter Value”...
Page 241: Reset Maintenance Counter
Touch Exit Config Menu to exit the Configuration Menu, and Resetting the Printer displays. The printer performs a POR, and the printer returns to the ready mode. Exit Config Menu Maintenance Counter Value 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.
Page 242: Print Quality Pages
USB Scan to Local To change the USB Scan to Local setting: 1. Touch to select USB Scan to Local from the Configuration Menu. 2. The panel displays the setting's name in the header and [setting's current value] below the header row.
Page 243: Size Sensing
Reports Menu Settings Page To print the Menu Settings Page, touch to select Menu Settings Page from Reports. The message Printing Menu Settings Page is displayed. The following settings are printed: Maintenance Counter Value USB Scan to Local Print Quality Pages Reports SIZE SENSING Panel Menu...
Page 244: Panel Menus
When the setting is Auto, every input option equipped with size sensing hardware automatically registers what size media it contains. When the setting is Off, the media size detected by hardware is ignored. The media size can be set by the operator panel or the data stream. To change the size sensing setting: 1.
Page 245: Factory Defaults
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 LXK Embedded Solutions applications (LES). Network does not appear unless you have a network printer.
Page 246: Min Copy Memory
Min Copy Memory 1. Touch to select Min Copy Memory from the Configuration Menu. The panel displays the setting's name in the header and [setting's current value] below the header row. 2. Touch to change the setting. For example, the values may be 25 MB, 35 MB, 50 MB, and 100 MB. The default is 25 MB. Values will only be displayed if the amount of installed DRAM is at least twice the amount of the value, that is, at least 200 MB of installed DRAM is required to display the 100 MB selection.
Page 247: Fb Edge Erase
3. Touch Submit to save the change. Touch Back to cancel and return to the Configuration Menu. FB Edge Erase The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the scanned image that will be erased. For copies, the printed page will have a 2 mm no-print border. The larger of the 2 mm no-print border and the Edge Erase setting will be used in this situation.
Page 248: Disable Scanner
d. Use the copy of the Quick Test page to adjust the Left Margin and Top Margin settings. e. Touch Submit. f. Touch Copy Quick Test and compare the new copy to the original. Repeat the flatbed alignment steps until the position on the page of the Quick Test copy closely matches the original.
Page 249: Action For Prompts
Touch Back to exit without changing the value. Action for Prompts 1. Touch to select Action for Prompts from the Configuration Menu. The panel displays the setting's name in the header and [setting's current value] below the header row. 2. Touch to change the value.
Page 250: Jobs On Disk
Jobs On Disk If the hard disk is installed, Jobs On Disk allows the user to delete buffered jobs saved on the disk. The values are Delete and Do Not Delete. To delete jobs saved on the disk: 1. Touch to select Jobs On Disk from the Configuration Menu.
Page 251: Wipe Disk
The entire process is complete when the progress bar appears completely shaded and the percentage indicator shows 100%. After completion, the panel returns to Disk Encryption. 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.
Page 252: Les Applications
LES Applications This disables all installed LXK Embedded Solution applications. The default is Enabled. 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.
Page 253: Exit Configuration Menu
Exit Configuration Menu Touch Exit Config Menu to exit the Configuration Menu. The printer performs a POR, and the printer returns to the ready mode. Exit Config Menu 3-41 Diagnostic aids...
Page 254: Printer Configurations
Printer configurations Note: Printer configuration may vary depending on your printer model. Basic models Automatic Document Feeder (ADF) Printer control panel Standard exit bin Multipurpose feeder 550-sheet tray (Tray 1) 550-sheet tray (Tray 2) Optional output bin CAUTION: 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 drawer.
Page 255: Printer Theory
Printer theory Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors PC drum Sensor (input) Standard bin full actuator and sensor (standard bin full) Diverter PC cartridge Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor...
Page 256: Functions Of Main Components
Model X658 paper path rolls and sensors PC drum Sensor (input) Standard bin full actuator and sensor (standard bin full) Diverter PC cartridge Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm assembly Functions of main components •...
Page 257: Rear Media Guide
Rear media guide 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.
Page 258 Media tray assembly Wear strips Side guides End guides 3-46 Service Manual...
Page 259 Detection of media size 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. Pick arm assembly Sensor (media empty) Media out actuator Sensor (media low) Pick roll assemblies...
Page 260 Sensor (media low) This sensor detects by the actuator position whether media in the media tray assembly is low. When the flag of the actuator blocks, then unblocks the sensing area of the sensor (media low), the media level is determined to be low.
Page 261: Sensor (Mpf Media Empty)
Sensor (MPF media empty) The sensor (MPF media out) detects whether media is present on the MPF. Supported paper sizes, types, and weights The following tables provide information on standard and optional paper sources and the types of paper they support.
Page 262 250-or 550-sheet Optional Multipurpose Paper size Dimensions trays (standard 2000-sheet Duplex unit feeder or optional tray DL Envelope 110 x 220 mm (4.3 x 8.7 in) Other Envelope 98 x 162 mm (3.9 x 6.4 in.) to 176 x 250 mm (6.9 x 9.8 in.) 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.
Page 263: Sensor (Input)
Registration Aligner assembly Sensor (input) Sensor (input) The sensor (input) is located just before the print cartridge and can detect whether media exists in the input path. Alignment assembly The alignment assembly is used to feed the media through the input path and to ensure that media is fed through the machine in a perfectly straight manner and not in a skewed manner.
Page 264: Transfer Roll Assembly
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.
Page 265: Polygon Printhead Assembly
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.
Page 266 Conceptual diagram of an image created by scanning Fuser Fuser unit assembly 3-54 Service Manual...
Page 267: Fuser Components
Fuser components 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. 3-55 Diagnostic aids...
Page 268: Pressure Roll
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. Heater lamp The heater lamp is a quartz glass tube containing a heater coil. A terminal is mounted to the end of the heater rod via a harness.
Page 269: Fuser Unit Assembly (Type 1 And Type)
Fuser unit assembly (type 1 and type 2) Type 1 fuser unit assembly In the type 1 fuser unit assembly, the detacs, which are used to prevent the media from sticking to the hot roll, do not make contact with the hot roller. The type 1 fuser unit assembly has a life of 300K. Hot roll Fuser lamp Non contact detac...
Page 270: Sensor (Standard Bin Full)
Exit The standard media exit ejects printed media from the printer to the standard bin . Sensor (standard bin full) The sensor (standard bin full) detects whether the standard bin is full by moving the actuator up and down. Drive Main drive motor assembly The main drive motor is a DC motor that drives the print cartridge, aligner, MFP and fuser.
Page 271: Electrical Components And Controller
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. Redrive motor assembly Main drive motor assembly Electrical components and controller Main cooling fan LVPS card LVPS assembly...
Page 272: Main Cooling Fan
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. Main cooling fan The main cooling fan discharges air from the printer to prevent excessive temperature increase.
Page 273: Printhead Control
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.
Page 274: Xerographic And Print Cartridge Components
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.
Page 275 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 Charge roll (-VDC)
Page 276 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 Drum Surface Image Voltage Laser Beam Laser Beam Discharge Level Invisible Latent Image Development The toner contained within the PC Cartridge has an electrical property that causes it to adhere to the development roll.
Page 277 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. HVPS Developer Metering Roll Blade Toner DRUM -VDC Drum Surface Drum Surface Image Voltage...
Page 278 negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper. HVPS -VDC DRUM -VDC 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.
Page 279: Auto Density Sensing
Auto density sensing 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.
Page 280: Document Scanning At Adf
Document scanning at ADF The document scanning section of this machine consists of a scanner that reads a single-sheet document placed on the platen glass and a document feeder that can transport a multiple-sheet document for one or two- sided scanning. Document scanning at platen Shown below is the operational overview of document scanning at the platen.
Page 281: Sensor (Fb Scanner Hp)
Sensor (FB scanner HP) A sensor that detects the HP position of the flatbed scanner CCD assembly. Scanner exposure lamp A xenon lamp to which the document is exposed. Scanner controller card assembly A card that controls the scanner section. Scanner cooling fan A fan that prevents overheating of the scanner controller card assembly and exposure lamp.
Page 282: Simplex And Duplex Document Feed
Shown below is the document feed path from the ADF. Duplex CCD Simplex and duplex document feed For two simplex document sheets, feed is performed in the following sequence: 1. The first document sheet is fed to the ADF transport roll assembly. 2.
Page 283: Names And Functions Of Components
4. As the image is scanned on both sides, the document sheet is fed and ejected by the ADF feed-out roll assembly and ADF exit roll assembly that are driven by the ADF transport motor. Transport motor Pick roll Feed motor Exit roll assembly Names and functions of components Sensor (ADF long media)
Page 284: Sensor (Adf Media Exit)
A card that controls the ADF unit assembly. The ADF controller card assembly is connected to and controlled by the Scanner controller card assembly. Sensor (ADF sheet through) The ADF sensor (ADF sheet through) is installed immediately downstream from the Feed/pick roll assembly to detect completion of document feed.
Page 285 This solenoid causes the ADF pick roll to be raised and lowered in order to properly pick the media. Sensor (ADF media length) Sensor (Media exit) Sensor (ADF media width) Sensor (ADF document set) Sensor (ADF lower door interlock) ADF pick solenoid Switch (ADF closed interlock) Sensor (ADF rear registration)
Page 286: High Capacity Input Tray (Hcit) Tray Assembly
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 3-74 Service Manual...
Page 287: Sheet/550-Sheet Tray Assembly
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.
Page 288: Media Level Sensing
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. 250-sheet tray Sensor A Sensor B...
Page 289 Pick arm assembly Sensor (media empty) Sensor (media low) Sensor (pass through) 250-sheet drawer assembly Pick arm assembly Sensor (media empty) Sensor (media low) Sensor (pass through) 550-sheet drawer assembly 3-77 Diagnostic aids...
Page 290 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. Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors PC drum Sensor (input)
Page 291 Model X658 paper path rolls and sensors PC drum Sensor (input) Standard bin full actuator and sensor (standard bin full) 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.
Page 292: Media Tray Assembly
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.
Page 293 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).
Page 294 Duplex 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. Sensor (duplex input) The sensor (duplex wait) detects whether media is remaining in the duplex. 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.
Page 295: Paper Jams
Paper jams 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.
Page 296 3. Push the release latch, and then open the front cover. 4. Lift and pull the print cartridge out of the printer. Warning: Do not touch the photoconductor drum on the underside of the cartridge. Use the cartridge handle whenever you are holding the cartridge. 5.
Page 297 6. 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. 7.
Page 298 3. Pull down the bottom rear door. 4. Push the tab down. 5. Remove the jammed paper. 6. Close the bottom rear door. 7. Insert the standard tray. 8. Touch Continue. 3-86 Service Manual...
Page 299 240–245 paper jams 1. Touch Status/Supplies to identify the location of the jam. 2. Pull the standard tray out. 3. Remove any jammed paper, and then close the tray. 4. Touch Continue. 5. If the jam message remains, then pull out any optional trays. 6.
Page 300 250 paper jam 1. Touch Status/Supplies to identify the location of the jam. 2. Remove the paper from the multipurpose feeder. 3. 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.
Page 301: X Staple Jams
3. 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. 4. Remove the envelope from the printer. Note: If you cannot remove the envelope, then the print cartridge will have to be removed. For more information, see “200 and 203 paper jams”...
Page 302 3. Pull the latch of the staple cartridge holder down, and then pull the holder out of the printer. 4. Use the metal tab to lift the staple guard, and then remove any loose staples. 5. Close the staple guard. 3-90 Service Manual...
Page 303 6. Press down on the staple guard until it snaps into place. 7. Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place. 8. Close the stapler door. 290–294 paper jams 1. Remove all original documents from the ADF. 2.
Page 304 4. Open the scanner cover, and then remove any jammed pages. 5. Open the bottom ADF door, and then remove any jammed pages. 6. Close the bottom ADF door and scanner cover. 7. Touch Restart Job. 3-92 Service Manual...
Page 305: Adjusting Skew
Adjusting skew For flatbed scanner and ADF skew adjustment, refer to the examples below to identify if “negative” or “positive” skew is present; this will help with determining the correct adjustment to be made. Acceptable ADF and flatbed scanner specifications Scan Flatbed (LE, TE, left &...
Page 306: Flatbed Scanner Skew Adjustment
Flatbed scanner skew adjustment 1. Remove the scanner cover, left. Go to “Scanner cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-134 or “Scanner cover, left removal (model X658)” on page 4-135. 2. To adjust flatbed scanner skew, loosen the screws (A) and slide the scanner rod mounting plate left or right accordingly and retighten screws (A).
Page 307 3. For negative skew, rotate the document tray clockwise as shown above. 4. For positive skew, rotate the document tray counterclockwise as shown above. 5. After skew correction has been made, tighten the document tray screws, and reinstall the ADF front and rear covers.
Page 308: Adf Skew Adjustment (Via Duplex Ccd Assembly)
ADF skew adjustment (Via duplex CCD assembly) 1. Remove the ADF cover, front. Go to “ADF cover, front removal” on page 4-64. 3-96 Service Manual...
Page 309 2. Loosen the M4 screw (A) on the right below. 3. Turn the skew adjustment screw (B) (to the left, below) appropriately - clockwise for negative skew and counterclockwise for positive skew. Note: Each full turn of the adjustment screw yields .5 mm of skew correction. The maximum adjustment is three turns for clockwise movement of the screw, and four turns for counterclockwise movement.
Page 310: Media Squareness Check
Media squareness check This test is critical when cut paper is being used to align the ADF skew during reworks. Pallets of quality paper may be found with more than 2 mm of skew. 1. Remove two consecutive pieces of paper from the ream. 2.
Page 311 3. This shows the final position of the two pages. 4. Tap the two pages on a flat surface until the bottom edge is aligned. 3-99 Diagnostic aids...
Page 312 5. Look closely at the top edge of the media to see if the sheets are aligned. Square Media: Top and sides are perfectly aligned The two pages do not align perfectly at the top or sides. Media Not square: DO NOT use for ADF skew rework.
Page 313: Print Skew Correction Procedure
Print skew correction procedure 1. Check the paper squareness. 2. Make sure the guides in the paper tray are properly aligned. 3. Check the base printer skew and registration. 4. Plug printer into the power source and power on in Diagnostics Mode (hold down 3 and 6 during POR). 5.
Page 314 7. Determine if the printer passes or fails the skew specifications based on the values listed on the table.. Skew Specification (L2-L1) (R2-R1) (T2-T1) (B2-B1) Letter 1.4 mm 1.4 mm 1 mm 1 mm 1.5 mm 1.5 mm Legal 1.8 mm 1.8 mm 8.
Page 315: Copy Skew Correction Procedure
Copy skew correction procedure Note: This specification is used for copies from the flatbed, front ADF, and back ADF. 1. Check the paper squareness. 2. Make sure the guides in the paper tray are properly aligned. 3. Check the printer skew and registration. 4.
Page 316 10. Determine if it passes or fails the skew specifications, based on the values listed in the table. Copy Skew Specification Measurement Specification Description (CopyL2-CopyL1) 2.0 mm Left Skew (CopyR2-CopyR1) 2.0 mm Right Skew (CopyT2-CopyT1) 1.5 mm Top Skew (CopyB2-CopyB1) 1.5 mm Bottom skew Copy Registration Specification...
Page 317: Security Reset Jumper
Security Reset Jumper The Security Reset Jumper is available on all high-end printer and MFP models, including the T650, T652, X652/5535dn, 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: •...
Page 318 3. Remove the small yellow jumper that covers a pair of the jumper’s pins. 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.
Page 319: Printer Skew Specifications
Printer skew specifications Abnormal skew printer correction STEP ONE: The repair operator should ev aluate the left edge of the paper to determine if the aligner is properly set. If the left vertical line is with the defined limit, parallel to the edge of the paper, the aligner is correct and properly set.
Page 320: Print Registration
Duplex Skew Specification Side: Print Sequence Thru Printer: 16 lb-to-24 lb +/-0.007 mm/mm +/-0.005 mm/mm All Other Papers +/-0.010 mm/mm +/-0.005 mm/mm Card Stock +/-0.007 mm/mm +/-0.007 mm/mm Labels: +/-0.010 mm/mm +/-0.010 mm/mm - Paper, Dual-Web Paper +/-0.010 mm/mm +/-0.010 mm/mm - Vinyl, Polyester (less than or equal 92# liner Print Registration...
Page 321: Repair Information
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). To prevent damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as turning off power before removing logic boards: •...
Page 322: Polygon Printhead Mechanical Registration Adjustment
Adjustments Polygon 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.
Page 323: Alignment Assembly Adjustment
Alignment assembly adjustment Note: Power the machine off before performing the adjustment. Note: In order to make the adjustment, the side cover, left must first be removed to access the adjusting hole in the system card. Do the alignment assembly adjustment whenever you replace the alignment assembly. It may also be necessary to perform a printhead adjustment after making the media skew adjustment.
Page 324: Fuser Solenoid Adjustment
a new test page until you obtain the results you want. Fuser solenoid adjustment Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap between the rear of the solenoid stator and the solenoid armature.
Page 325: Removal Procedures
Removal procedures Before starting service work CAUTION: Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly. CAUTION: While performing service around the fuser assembly, ensure the fuser area has cooled down. Note: Some removal procedures require removing cable ties.
Page 326: Charge Roll Assembly Removal
Charge roll assembly removal WARNING: When removing the charge roll assembly, avoid touching the charge roll surface. 1. Open the MPF door assembly. 2. Open the operator panel door assembly or the print cartridge door assembly. 3. Detach the left side of the charge roll assembly from the machine. 4.
Page 327: Duplex Assembly Removal
Duplex assembly removal 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. See “Duplex drive motor assembly removal” on page 4-9. 2.
Page 328: Duplex Cooling Fan Removal
Duplex cooling fan removal 1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and X656)” on page 4-122. 2. Remove the screw (A) securing the duplex cooling fan to the machine. 3. Disconnect the connector (B) from the duplex cooling fan.
Page 329: Duplex Drive Motor Assembly Removal
Duplex drive motor assembly removal 1. Remove the fuser access door. See “Fuser access door assembly removal” on page 4-12. 2. Remove the cover assembly, rear lower. See “Cover assembly, rear lower (X654, X656, and X658)” on page 4-38. 3. Remove the three screws (A) securing the duplex drive motor assembly to the machine. Note: When removing the duplex drive motor assembly, the upper duplex drive belt (B) will become detached.
Page 330: Duplex Input Sensor Assembly Removal
7. Remove the harness (E) from the duplex drive motor assembly. 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 1.
Page 331 4. Detach the front right duplex guide spring (B) from the duplex guide assembly, front. 5. Fully open the duplex guide assembly, front 90°, and detach it from the machine. 6. Remove the duplex guide assembly, front. 4-11 Repair information...
Page 332: Media Turn Guide Removal
Media turn guide removal 1. Remove the MPF tray door assembly. See “Operator panel assembly removal (model X658)” on page 4-109 or “MPF tray door assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-97. 2. Gently bend the left side of the media turn guide to release the hook (A) as shown in the picture.
Page 333 2. Press the two tabs (A) on the fuser access door assembly, and detach it from the machine. 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. 4-13 Repair information...
Page 334: Main Cooling Fan Removal
Main cooling fan removal 1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123. 2. Remove the six screws (A) securing the metal shield to the machine.
Page 335: Fuser Drive Release Linkage Removal
7. Remove the fuser cooling fan connection (C). Fuser drive release linkage removal 1. Remove the system card assembly. See “System card assembly removal” on page 4-50. 2. Gently unsnap the upper end of the fuser drive release linkage from the machine. 3.
Page 336: Fuser Wiper Cover Assembly Removal
5. While pressing the two buttons (A), pull the fuser unit assembly from the machine. 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 1.
Page 337: Hvps Card Assembly Removal
HVPS card assembly removal 1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121. 2. Remove the four screws (A) securing the HVPS card assembly to the machine.
Page 338: Option Drive Shaft Removal
2. Release the two hooks (A) securing the lower portion of the inner deflector to the machine. 3. Remove the inner deflector. Replacement Warning: When replacing the inner deflector, ensure that it is properly installed, or jamming will occur. Option drive shaft removal 1.
Page 339 3. Remove the spring. 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. 4-19 Repair information...
Page 340: Main Drive Motor Assembly Removal
Main drive motor assembly removal 1. Remove the system card assembly. See “System card assembly removal” on page 4-50. 2. Remove the fuser drive release linkage. See “Fuser drive release linkage removal” on page 4-15. 3. Close the operator panel door assembly. 4.
Page 341: Alignment Assembly Removal
(C), or jamming will occur. See “Alignment assembly adjustment” on page 4-3. 1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
Page 342 6. Remove the two screws (B) securing the alignment assembly to the machine. 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.
Page 343: Media Out Actuator Removal
Media out actuator removal 1. Remove the pick arm assembly. See “Pick arm assembly removal” on page 4-29. 2. Release the hook (A) securing the media out actuator to the unit. 3. Remove the media out actuator. Media support removal 1.
Page 344: Mpf Cam Gear Removal
Tray roller catch assembly removal 1. Remove the media tray. 2. Remove the HVPS card assembly. See “HVPS card assembly removal” on page 4-17. 3. Release the spring from the machine. Note: The tray roller catch assembly should be removed from the media tray cabinet. 4.
Page 345: Mpf Lift Plate Assembly Removal
MPF lift plate assembly removal 1. Remove the media turn guide. See “Media turn guide removal” on page 4-12. 2. Remove the four screws (A) securing the MPF lift plate assembly to the machine. 3. Gently detach the MPF lift plate assembly. 4.
Page 346: Mpf Pick Roll Assembly Removal
1. Remove the MPF lift plate assembly. See “MPF lift plate assembly removal” on page 4-25. 2. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
Page 347 4. Remove the metal cover. 5. Remove the screw (B) securing the MPF pick solenoid assembly to the machine. 6. Remove the MPF pick solenoid assembly. 4-27 Repair information...
Page 348 7. Disconnect the connection (C) from the MPF pick solenoid assembly. 4-28 Service Manual...
Page 349: Pick Arm Assembly Removal
Pick arm assembly removal 1. Remove the media tray from the machine. 2. Place the machine on the left or right side. 3. Remove the spring (A). 4. Remove the two E-clips (B) securing the pick arm assembly to the machine. 4-29 Repair information...
Page 350 5. Remove the screw (C) securing the pick arm assembly to the machine. 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.
Page 351: Pick Roll Assembly Removal
Replacement Warning: When replacing the pick roll assembly, do not touch the rubber surface. Print cartridge cooling fan removal 1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121.
Page 352: Print Cartridge Clamp Assembly Removal
Note: This procedure can be applied to the left or right printer cartridge hold down assembly. 1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on page 4-106 or “Laser cover removal (model X658)” on page 4-104.
Page 353: Print Cartridge Id Connector Assembly Removal
Print cartridge ID connector assembly removal 1. Remove the print cartridge. 2. Remove the main drive motor assembly. See “Main drive motor assembly removal” on page 4-20. 3. Release the two hooks (A) securing the print cartridge ID connector assembly to the machine. 4.
Page 354: Printhead Assembly Removal
See “Polygon printhead mechanical registration adjustment” on page 4-2. 1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on page 4-106 or “Laser cover removal (model X658)” on page 4-104.
Page 355: Connection Access Cover, Rear Removal
5. Remove the four screws (C) securing the printhead assembly to the machine. 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. See “Polygon printhead mechanical registration adjustment” on page 4-2.
Page 356 Door assembly, rear removal 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.
Page 357 6. Detach the rear duplex guide spring (C). 7. Remove the duplex guide assembly, rear. 8. Remove the screw (D) securing the rear duplex guide handle to the assembly. 9. Remove the duplex guide assembly, rear. 4-37 Repair information...
Page 358: Cover Assembly, Rear Lower (X654, X656, And X)
3. Remove the cover assembly, rear lower. Redrive motor assembly removal 1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on page 4-106 or “Laser cover removal (model X658)” on page 4-104. 2. Remove the six screws (A) securing the metal cover to the machine.
Page 359 3. Remove the metal cover. 4. Disconnect the connection (B) from the redrive motor assembly. 5. Disconnect the connection (C) from the sensor (standard media bin full). 4-39 Repair information...
Page 360 6. Release the hooks (D) securing the output option interface cable assembly to the machine. 7. Detach the output option cable assembly. 8. Remove the two screws (E) securing the redrive motor assembly to the machine. 9. Remove the redrive motor assembly. 4-40 Service Manual...
Page 361: Sensor (Toner Empty) Removal
Sensor (duplex input) removal 1. Remove the duplex input sensor assembly. See “Duplex input sensor assembly removal” on page 4-10. 2. Release the hooks (A) securing the senor (duplex media path) to the bracket. 3. Remove the sensor (duplex input). Sensor (media low) removal 1.
Page 362: Sensor (Input) Removal
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). Sensor (input) removal 1. Remove the inner deflector. See “Inner deflector removal” on page 4-17. 2.
Page 363 2. Gently unsnap the sensor shield assembly from the machine. 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. 4-43 Repair information...
Page 364: Standard Bin Actuator Assembly Removal
Standard bin actuator assembly removal 1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on page 4-106 or “Laser cover removal (model X658)” on page 4-104. 2. Disconnect the connection (A) from the standard bin actuator assembly.
Page 365: Sensor (Toner Density) Removal
4. Disconnect the connection (B) to the sensor (toner density). Switch (media size) assembly removal 1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
Page 366 5. Gently place the machine on the left of right side. 6. Release the two hooks (B) securing the switch (media size) assembly to the machine. 7. Remove the switch (media size) assembly. 8. Disconnect the connection (C) from the switch (media size) assembly. 4-46 Service Manual...
Page 367: Lvps Card Assembly Removal
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36. 2. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121.
Page 368 6. Disconnect the connector (C) from the LVPS card assembly. 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.
Page 369: Access Door Removal
Access door removal 1. Open the access door. 2. Gently detach the two hinges (A) of the access door from the machine. 3. Remove the access door. 4-49 Repair information...
Page 370: System Card Assembly Removal
It must be returned to the manufacturer. 1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
Page 371 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.
Page 372 WARNING: When removing the system card assembly from the machine, ensure that the LVPS assembly connection (C) does not become damaged. 7. Remove the system card assembly. 8. Remove any remaining screws securing the system card assembly to the metal box. 9.
Page 373: Hard Drive Removal
Hard drive removal 1. Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123. 2. Loosen the two screws (A) securing the hard drive to the rear of the machine. 3. Remove the system card metal plate. 4.
Page 374: Hard Drive Cooling Fan Removal
Hard drive cooling fan removal 1. Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123. 2. Remove the system card metal plate. 3. Loosen the five screws securing the fan mounting bracket to the machine. 4.
Page 375: Fax Card Assembly Removal
Fax card assembly removal 1. Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123. 2. Remove the system card metal plate. 3. Loosen the two screws (A) securing the fax card assembly to the rear of the machine. 4.
Page 376: Transfer Roll Assembly Removal
Transfer roll assembly removal 1. Open the operator panel door assembly. 2. Remove the print cartridge. 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. 4-56 Service Manual...
Page 377: Transfer Roll Bracket Assembly, Left Removal
Transfer roll bracket assembly, left removal 1. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-56. 2. Remove the inner deflector. See “Inner deflector removal” on page 4-17. 3. Remove the screw (A) securing the transfer roll bracket assembly, left to the machine. 4.
Page 378 3. Remove the screw (A) securing the transfer roll bracket assembly, right to the machine. 4. Remove the transfer roll bracket assembly, right. 4-58 Service Manual...
Page 379: Transfer Deflector Removal
Transfer deflector removal 1. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-56. 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. 5.
Page 380: Redrive Assembly Removal
Redrive assembly removal 1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36. 2. Open the fuser access door. 3. Remove the two screws (A) securing the redrive assembly to the machine. 4. Press the two tabs (B) to release the redrive assembly to the machine. While pressing the two tabs (B), pull the redrive assembly from the machine.
Page 381: Adf Feed / Pick Roll Assembly Removal
Rear Right Front Left ADF feed / pick roll assembly removal 1. Lift the ADF top door assembly. 2. Slide the ADF pick roll assembly to the front. 3. Lift the rear of the ADF pick roll assembly. 4. Remove the ADF pick roll assembly. 4-61 Repair information...
Page 382: Adf Separator Roll Removal
ADF separator roll removal 1. Lift the ADF top door assembly. 2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61. 3. Remove the access cover. 4. Press tab (A), and slide the separator roll off the shaft. 4-62 Service Manual...
Page 383: Adf Separator Torque Limiter Assembly Removal
ADF separator torque limiter assembly removal 1. Lift the ADF top door assembly. 2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61. 3. Remove the access cover. 4. Press tab (A), and slide the separator roll off the shaft. 4-63 Repair information...
Page 384: Adf Cover, Front Removal
5. Slide the ADF separator torque limiter assembly to the front, and remove. ADF cover, front removal 1. Lift the ADF top door assembly. 2. Remove two screws (A) from the top of the front cover assembly. 3. Remove one screw (B) from the bottom of the ADF cover, front. 4.
Page 385: Adf Cover, Rear Removal
ADF cover, rear removal 1. Lift the ADF left door cover. 2. Remove two metal screws (A). 3. Remove the plastic screw (B) from the right side of the ADF cover, rear. 4. Remove the ADF cover, rear. ADF document tray assembly removal 1.
Page 386: Adf Top Door Assembly Removal
ADF top door assembly removal 1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64. 2. Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65. 3. Lift the ADF top door assembly. 4.
Page 387: Adf Controller Card Removal
7. Pry out the front tabs (D). 8. Remove the ADF top door assembly. ADF controller card removal 1. Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65. 2. Disconnect all cables attached to the controller card. 3.
Page 388: Adf Platen Cushion Removal
ADF platen cushion removal 1. Lift the ADF unit assembly. 2. Unfasten the velcro. 3. Remove the ADF platen cushion. ADF lower door assembly removal 1. Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68. 2. Open the ADF bottom door by pressing the green tab (A) on the underside of the front of the ADF unit assembly.
Page 389: Adf Duplex Ccd Scan Glass Assembly Removal (X654, X656, And X)
ADF duplex CCD scan glass assembly removal (X654, X656, and X658) 1. Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68. 2. Open the ADF lower door assembly. 3. Remove four screws (A) from the ADF duplex CCD scan glass assembly. 4.
Page 390: Adf Duplex Ccd Assembly Removal (X654, X656, And X)
ADF duplex CCD assembly removal (X654, X656, and X658) CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the product where you are working. Unplug the product before you begin, or use caution if the product must receive power in order to perform the task.
Page 391 4. Remove the two screws (C) securing the paper guide and remove. 5. Remove the three screws (D) from the underside of the ADF unit assembly securing the ADF duplex CCD assembly to the ADF. 6. Carefully, remove the ADF duplex CCD assembly from the underside of the ADF unit assembly. Replacement note: You must adjust skew after reinstalling the ADF duplex CCD assembly.
Page 392: Adf Pinch Roll Assembly Removal
ADF pinch roll assembly removal 1. Remove the ADF top door assembly. See “ADF top door assembly removal” on page 4-66. 2. Remove the two screws (A) on either side of the ADF pinch roll assembly. 3. Remove the ADF pinch roll assembly. 4-72 Service Manual...
Page 393: Adf Turn Guide Removal
ADF turn guide removal 1. Remove the ADF pinch roll assembly. See “ADF pinch roll assembly removal” on page 4-72. 2. Remove the ADF separator torque limiter assembly. See “ADF separator torque limiter assembly removal” on page 4-63. 3. Remove the two screws (A) from the front side. Be sure to secure the ground strap by the upper turn guide screw when reinstalling.
Page 394: Adf Media Pinch Pad Assembly Removal
5. Pivot the turn guide out from the front side, giving room to dislodge the locating pins (B) from the rear. 6. Remove the ADF turn guide. ADF media pinch pad assembly removal 1. Remove the ADF duplex CCD assembly. See “ADF duplex CCD assembly removal (X654, X656, and X658)”...
Page 395 4. Remove the four screws (A) securing the ADF media pinch pad assembly. 5. Remove the ADF media pinch pad assembly. 4-75 Repair information...
Page 396: Sensor (Adf Media Exit) Fan Bracket Assembly Removal (X654, X656, And X)
Sensor (ADF media exit) fan bracket assembly removal (X654, X656, and X658) 1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64. 2. Remove the ADF rear cover. See “ADF cover, rear removal” on page 4-65. 3.
Page 397: Adf Transport Drive Motor Bracket Assembly W/Cable Removal
ADF transport drive motor bracket assembly w/cable removal 1. Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65. 2. Remove the ADF transport drive motor bracket tension spring (A). 3. Remove the wires from the retaining clip (B) on top of the bracket. 4.
Page 398 5. Remove the bushing from the pick roll feed shaft. 6. Remove the six screws (B) securing the ADF feed motor assembly to the ADF unit assembly. 7. Remove the ADF feed motor assembly to include two belts and cable. 4-78 Service Manual...
Page 399: Adf Pick Roll Position Cam Assembly Removal
ADF pick roll position cam assembly removal 1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64. 2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61. 3.
Page 400: Adf Solenoid Assembly Removal
ADF solenoid assembly removal 1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64. 2. Remove the pick roll position cam assembly spring from the cam shaft lever. 3. Disconnect the solenoid wire harness. 4. Remove the two screws (A) securing the solenoid bracket assembly to the frame of the ADF unit assembly.
Page 401: Sensor (Adf 2Nd Scan) Removal
Sensor (ADF lower door interlock) removal 1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64. 2. Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68. 3. Open the bottom door assembly. 4.
Page 402: Sensor (Adf Sheet Through) Removal
4. Remove the sensor (ADF 2nd scan). Sensor (ADF 1st scan) removal 1. Remove the ADF turn guide. See “ADF turn guide removal” on page 4-73. 2. Remove the screw (A) securing the sensor (ADF first scan) to its bracket. 3.
Page 403: Sensor (Adf Document Set) Removal
Sensor (ADF document set) removal 1. Remove the ADF document tray assembly. See “ADF document tray assembly removal” on page 4-65. 2. Remove the three screws (A) securing the separator guide to the ADF frame. 3. Remove the sensor (ADF document set) harness. 4.
Page 404: Switch (Adf Closed Interlock) Removal
6. Remove the screw (C) securing the sensor (ADF document set) to the bracket. Switch (ADF closed interlock) removal 1. Remove the ADF cover, rear assembly. See “ADF cover, rear removal” on page 4-65. 2. Open the ADF unit assembly. 3.
Page 405: Adf Unit Assembly Removal (Model X)
2. Remove the scanner cover, left. See “Scanner cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-134. Note: Models X651and X652/5535dn do not need the left scanner cover removed (no duplex ADF cable). 3. Slide the left scanner cover to the rear, and remove.
Page 406: Adf Left Hinge Removal
3-93. ADF left hinge removal 1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-85 or “ADF unit assembly removal (model X658)” on page 4-85. 2. Remove the ADF feed motor bracket assembly with cable. See “ADF feed drive motor assembly removal”...
Page 407: Adf Right Hinge Removal
4. Remove the ADF left hinge. ADF right hinge removal 1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-85 or “ADF unit assembly removal (model X658)” on page 4-85.
Page 408: Cover, Left Rear Corner Removal (Model X)
Cover, left rear corner removal (model X658) 1. Remove the scanner support cover, left rear. See “Scanner support cover, left rear removal (model X658)” on page 4-150. 2. Remove the two screws (A) securing the cover, left rear corner to the machine. 3.
Page 409: Sensor (Standard Bin Exit) Actuator Assembly Removal
1. Open the upper rear door. 2. Remove the fuser access panel. 3. Remove the redrive assembly. See “Redrive assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-103 or “Redrive assembly removal (model X658)” on page 4-103. 4-89...
Page 410: Sensor (Adf Media Exit) Bracket Assembly Removal (X)
4. Using a flat-blade screwdriver, press on the tab (A) securing the sensor (standard bin exit) actuator assembly. 5. Position the sensor (standard bin exit) actuator assembly where the laser cover can be removed. 6. Remove the laser cover. See “Laser cover removal (model X658)” on page 4-104. 7.
Page 411: Scanner Ccd Assembly Removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 412 3. Pull slack in the carriage belt, and retighten screw (A). 4. Slide the carriage belt out of the rear of the scanner CCD assembly. 5. Remove the rear CCD scanner shaft (B) from the flatbed frame, by lifting the left end of the shaft up and remove through the left side.
Page 413: Scanner Reference Led Cable Assembly Removal
Scanner reference LED cable assembly removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 414: Scanner Unit Assembly Removal (Models X651, X652/5535Dn, X654, And X)
Once a component has been installed in a machine and powered up into user mode, it cannot be used in another machine. It must be returned to the manufacturer. 1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-85.
Page 415 7. Remove the screw (D) securing the ground strap to the frame of the scanner unit assembly. 8. Carefully slide the scanner unit assembly to the front, and lift up. 4-95 Repair information...
Page 416: Scanner Unit Assembly Removal (Model X)
Scanner unit assembly removal (model X658) Warning: When replacing any of the following components: • Scanner interface card assembly • System card assembly • Scanner unit assembly Only replace one component at a time. replace the required component and perform a POR before replacing a second component listed above.
Page 417: Mpf Tray Door Assembly Removal (Models X651, X652/5535Dn, X654, And X)
MPF tray door assembly removal (models X651, X652/5535dn, X654, and X656) 1. Open the MPF tray door. 2. Carefully pry the left and right manual feeder tabs out of the slots in the manual feed tray. 3. Rotate the manual feeder vertical and pull straight up to remove the feeder.
Page 418 5. Bow the door slightly to remove the right side hinge pin. 6. Slide the door assembly to the left until the door clears all the pins (B). 4-98 Service Manual...
Page 419: Mpf Tray Door Assembly Removal (Model X)
7. Continue to slide the MPF tray door assembly to the left, and remove. MPF tray door assembly removal (model X658) 1. Open the MPF tray door assembly. 2. Remove the MPF media guide assembly. See “MPF media guide assembly removal (model X658)” on page 4-108.
Page 420 4. Remove the left clip (B) securing the front door tension link. 5. Remove the left tension link. 6. Pull the right tension link from the hinge. 7. Slide the MPF tray door assembly to the left until all the bosses clear the hinges. 8.
Page 421: Fuser Access Assembly Removal
Output cover assembly removal (model X651, X652/5535dn, X654, and X656) 1. Open the door assembly, rear. Note: If you do not have a short screwdriver, remove the scanner unit assembly. See “Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-94. 4-101 Repair information...
Page 422: Output Cover Assembly Removal (Model X)
2. Remove the three screws (A) securing the output cover assembly to the machine. 3. Remove the output cover assembly. Output cover assembly removal (model X658) 1. Open the door assembly, rear. 2. Lift the right side of the fuser exit access panel and remove. 4-102 Service Manual...
Page 423: Redrive Assembly Removal (Models X651, X652/5535Dn, X654, And X)
4. Release the left and right clips (B). 5. Remove the redrive assembly. Redrive assembly removal (models X651, X652/5535dn, X654, and X656) 1. Remove the fuser access assembly. See “Fuser access assembly removal” on page 4-101. 2. Remove the two screws (A) securing the redrive assembly to the machine.
Page 424: Laser Cover Removal (Model X)
4. Release the left and right clips (B). 5. Remove the redrive assembly. Laser cover removal (model X658) 1. Remove the ADF unit assembly . See “ADF unit assembly removal (model X658)” on page 4-85. 2. Remove the scanner unit assembly. See “Scanner unit assembly removal (model X658)” on page 4-96. 3.
Page 425 5. Remove the five screws (A) on the left securing the laser cover. 6. Remove the four screws on the right (B) securing the laser cover. 7. Remove the sensor (ADF media exit) fan bracket assembly. See “Sensor (standard bin exit) actuator assembly removal”...
Page 426: Laser Cover Removal (Models X651, X652/5535Dn, X654, And X)
9. Remove the laser cover. Laser cover removal (models X651, X652/5535dn, X654, and X656) 1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-85. 2. Remove the scanner unit assembly. See “Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656)”...
Page 427 6. Remove the three screws (B) on either side of the laser cover. 7. Remove the redrive assembly. See “Redrive assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-103. 8. Remove the sensor (ADF media exit) bracket assembly. See “Sensor (ADF media exit) bracket assembly removal (X651)”...
Page 428: Standard Output Bin Led Assembly Removal (Models X651, X652/5535Dn, X654, And X)
Standard output bin LED assembly removal (models X651, X652/5535dn, X654, and X656) 1. Remove the scanner from the scanner support platform. See “Scanner support platform removal (models X651, X652/5535dn, X654, and X656)” on page 4-141. 2. Remove screw (A) securing standard output bin LED assembly to the scanner support platform.
Page 429: Operator Panel Assembly Removal (Model X)
3. Push the spring on the right side down, and remove the MPF media guide assembly, by rotating the assembly vertical and lift up. Operator panel assembly removal (model X658) 1. Pull the operator panel door assembly forward, and remove. 2.
Page 430 4. Remove the cover strip (C) from the operator panel assembly. 5. Remove the three screws (D) securing the operator panel assembly. 6. Slide the operator panel assembly to the left. 7. Rotate the operator panel assembly upside down, and remove the three screws (E). 8.
Page 431: Card Reader Assembly Removal (Model X)
Card reader assembly removal (model X658) 1. Remove the operator panel assembly. See “Operator panel assembly removal (model X658)” on page 4-109. 2. Turn over the operator panel assembly. 3. Remove the 3 screws (A) from the back of the operator panel assembly. 4.
Page 432 5. Remove the four screws (C) securing the the card reader bracket to the lower panel. 6. Remove the bracket (D). 7. Remove the card reader assembly (E). 4-112 Service Manual...
Page 433 8. Disconnect the cable (F) from the card reader. 4-113 Repair information...
Page 434: Usb Cable Removal (Model X)
USB cable removal (model X658) 1. Remove the operator panel assembly. See “Operator panel assembly removal (model X658)” on page 4-109. 2. Turn over the operator panel assembly. 3. Remove the 3 screws (A) from the back of the operator panel assembly. 4.
Page 435: Operator Panel Door Assembly Removal (Models X651, X652/5535Dn, X654, And X)
7. Disconnect the USB Cable. Operator panel door assembly removal (models X651, X652/5535dn, X654, and X656) 1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on page 4-106. 2. Remove the counter balance springs (A) on both sides.
Page 436 5. Remove the pins (D) on both sides securing the links. 4-116 Service Manual...
Page 437 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. 7. Remove the printer controller card cage cover. 8.
Page 438 9. Lift the operator panel door assembly out of the machine. 4-118 Service Manual...
Page 439 Operator panel cover latch assembly removal (models X651, X652/5535dn, 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.
Page 440: Print Cartridge Cover Assembly Removal (Model X)
Print cartridge cover assembly removal (model X658) 1. Open the print cartridge cover assembly. 2. Remove the two screws (A) securing the print cartridge cover assembly. 3. Remove the cartridge access door. 4-120 Service Manual...
Page 441: Side Cover, Right Removal (Model X)
Side cover, right removal (model X658) 1. Remove the cover, left rear corner. See “Cover, left rear corner removal (model X658)” on page 4-88. 2. Open the front door. 3. Open the cartridge access door. 4. Remove the screw (A), and pull the side cover, right up and out to remove. 4-121 Repair information...
Page 442: Side Cover, Right Removal (Models X651, X652/5535Dn, X654, And X)
Side cover, right removal (models X651, X652/5535dn, X654, and X656) 1. Remove the door assembly, rear assembly. See “Door assembly, rear removal” on page 4-124. 2. Remove the cover, rear lower. See “Cover, rear lower removal” on page 4-125. 3. Open the paper tray.
Page 443: Side Cover, Left Removal (Models X651, X652/5535Dn, X654, And X)
3. Release the two tabs (A) in the front. 4. Remove the side cover, left. Side cover, left removal (models X651, X652/5535dn, X654, and X656) 1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124. 2. Remove the rear lower door. See “Cover, rear lower removal” on page 4-125.
Page 444 6. Remove the three screws (A) securing the side cover, left to the machine. 7. Remove the side cover, left by pulling out the tabs on the top and bottom and by pulling the cover out of its rear hinges. Door assembly, rear removal 1.
Page 445: Cover, Rear Lower Removal
4. Remove the door assembly, rear. Cover, rear lower removal 1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124. 2. Remove the two screws (A) on each side of the cover. 3. Open the cover, rear lower. 4-125 Repair information...
Page 446 4. Remove the remaining two screws (B). 5. Lift and remove the cover, rear lower. 4-126 Service Manual...
Page 447: Scanner Support Cover, Right Rear Removal (Model X)
Scanner support cover, right rear removal (model X658) 1. Remove the four screws (A) securing the scanner support cover, right rear to the machine. 2. Remove the scanner support cover, right rear. 4-127 Repair information...
Page 448: Scanner Support Inner Cover, Right Removal (Model X)
Scanner support inner cover, right removal (model X658) 1. Remove the scanner support cover, right rear. See “Scanner support cover, right rear removal (model X658)” on page 4-127. 2. Remove the four screws (A) securing the scanner support inner cover, right to the machine. 3.
Page 449: Scanner Support Cover, Right Removal (Model X)
Scanner support cover, right removal (model X658) 1. Remove the scanner support inner cover, right. See “Scanner support inner cover, right removal (model X658)” on page 4-128. 2. Remove the four (A) screws securing the scanner support cover, right to the machine. 3.
Page 450 3. Remove eight screws (A) securing the scanner controller cage cover to the cage. 4. Remove the scanner controller card cage cover. 5. Disconnect all the harnesses and ribbon cables. 4-130 Service Manual...
Page 451 6. Remove the seven screws (B) securing the card to the cage. 7. Remove the scanner controller card. 4-131 Repair information...
Page 452: Scanner Controller Card Assembly Removal (Models X651, X652/5535Dn, X654, And X)
Scanner controller card assembly removal (models X651, X652/5535dn, X654, and X656) 1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and X656)” on page 4-123. 2. Remove eight screws (A) securing the scanner controller cage cover to the cage.
Page 453: Scanner Cover, Rear Removal
4. Disconnect all the harnesses and ribbon cables. 5. Remove the seven screws (B) securing the card to the cage. 6. Remove the scanner controller card. Scanner cover, rear removal 1. Remove the four screws (A) securing the scanner cover, rear to the scanner. 2.
Page 454 Scanner cover, left removal (models X651, X652/5535dn, X654, and X656) 1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133. 2. Remove the metal screw (A) and plastic screw (B) securing the scanner cover, left to the scanner assembly.
Page 455: Scanner Cover, Left Removal (Model X)
Scanner cover, left removal (model X658) 1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133. 2. Remove the metal screw (A) securing the scanner cover, left to the scanner assembly. 3. Slide the scanner cover, left to the rear, and remove. 4-135 Repair information...
Page 456: Scanner Cover, Right Removal (Model X)
Scanner cover, right removal (models X651, X652/5535dn, X654, and X656) 1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133. 2. Remove the plastic screw (A) and metal screw (B) securing the scanner cover, right to the scanner.
Page 457 Scanner cover, front removal (models X651, X652/5535dn, X654, and X656) 1. Open the ADF cover. 2. Firmly grasp one side of the scanner cover, front. 3. Pull and remove the scanner cover, front. Scanner cover, front removal (model X658) 1. Remove the scanner cover, right. See “Scanner cover, right removal (model X658)” on page 4-136.
Page 458 3. Slide the scanner cover, front to the right, and remove. Replacement note: Always replace the scanner cover, front before replacing the scanner cover, right. 4-138 Service Manual...
Page 459: Scanner Platen Glass Cover Assembly Removal (Model X)
Scanner platen glass cover assembly removal (model X658) 1. Remove the ADF unit assembly. See “ADF unit assembly removal (model X658)” on page 4-85. 2. Remove the scanner cover, left. See “Scanner cover, left removal (model X658)” on page 4-135. 3.
Page 460 Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656) 1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-85. 2. Remove the scanner cover, front. See “Scanner cover, front removal (models X651, X652/5535dn, X654, and X656)”...
Page 461: Scanner Support Platform Removal (Models X651, X652/5535Dn, X654, And X)
Scanner support platform removal (models X651, X652/5535dn, X654, and X656) 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140. 2. Remove six screws (A) securing the scanner support platform to the scanner flatbed frame.
Page 462 9. If the scanner support platform needs to be removed from the printer, remove the four mounting screws as outlined in the “scanner unit assembly removal”. See “Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-94. 4-142...
Page 463: Carriage Belt Tensioner Assembly Removal
Carriage belt tensioner assembly removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 464: Carriage Drive Motor Assembly With Cable Removal
Carriage drive motor assembly with cable removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 465: Carriage Belt Removal
Carriage belt removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139. 2. Loosen the screw (A) on the carriage belt tensioner.
Page 466 6. Slide the carriage belt out of the rear side of the CCD carriage assembly. 4-146 Service Manual...
Page 467: Scanner / Adf Duplex Ccd Exposure Lamp Removal
Scanner / ADF duplex CCD exposure lamp removal 1. Remove the scanner CCD assembly or the ADF duplex CCD assembly. See “Scanner CCD assembly removal” on page 4-91 or “ADF duplex CCD assembly removal (X654, X656, and X658)” on page 4-70. 2.
Page 468: Scanner Interface Card Assembly Removal
6. Remove the scanner exposure lamp wiring harness from the clips (D) on the CCD assembly. 7. Remove the scanner exposure lamp by lifting up on the rear end and pulling the lamp out of the grommet. Scanner interface card assembly removal 1.
Page 469: Scanner Cooling Fan Filter Removal
Scanner cooling fan removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 470: Scanner Support Cover, Left Rear Removal (Model X)
Scanner support cover, left rear removal (model X658) 1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133. 2. Remove the two inner screws (A) and two screws (B) on the rear face securing the scanner support cover, left rear to the machine.
Page 471: Scanner Support Cover, Left Front Removal (Model X)
Scanner support cover, left front removal (model X658) 1. Open the front door assembly. 2. Remove the two screws (A) on the scanner support cover, left front to the machine. 3. Remove the scanner support cover, left front. 4-151 Repair information...
Page 472: Scanner Support Cover, Left Removal (Model X)
Scanner support cover, left removal (model X658) 1. Remove the scanner support cover, left rear. See “Scanner support cover, left rear removal (model X658)” on page 4-150. 2. Remove the scanner support cover, left front. See “Scanner support cover, left front removal (model X658)”...
Page 473: Sensor (Platen Glass Length) Assembly Removal
Sensor (platen glass length) assembly removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 474: Sensor (Scanner Hp) Assembly W/Bracket Removal
Sensor (scanner HP) assembly w/bracket removal 1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover assembly removal (model X658)” on page 4-139.
Page 475 4. Remove the LVPS cooling fan. 4-155 Repair information...
Page 476: Option Removals
Option removals High capacity input tray 4-156 Service Manual...
Page 477: High Capacity Input Tray (Hcit) Media Tray Assembly Removal
High capacity input tray (HCIT) media tray assembly removal 1. Open the HCIT media tray assembly until it reaches a stop. 2. Press the latch (A) down on the left side of the HCIT tray slide, and press the latch (B) up on the right side of the HCIT tray slide.
Page 478: High Capacity Input Tray (Hcit) Tray Cover, Front Removal
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. 4-158 Service Manual...
Page 479 3. Remove the HCIT tray cover, front. 4-159 Repair information...
Page 480: High Capacity Input Tray (Hcit) Cover, Rear Removal
High capacity input tray (HCIT) cover, rear removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the four screws (A) securing the HCIT cover, rear to the drawer. 4-160 Service Manual...
Page 481 2. Remove the HCIT cover, rear. 4-161 Repair information...
Page 482: High Capacity Input Tray (Hcit) Cover, Right Removal
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. See “High capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-165. 1.
Page 483 4. Remove the HCIT cover, right. 4-163 Repair information...
Page 484: High Capacity Input Tray (Hcit) Cover, Left Removal
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. See “High capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-165. 1.
Page 485: High Capacity Input Tray (Hcit) Anti-Tip Latch Assembly Removal
4. 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;...
Page 486 1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164. Note: The left side anti-tip assembly will come off when removing the HCIT cover, left. 4-166 Service Manual...
Page 487: High Capacity Input Tray (Hcit) Drawer Slide Assembly Removal
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.
Page 488 3. Disconnect the HCIT tray lift drive motor cable connector from the HCIT controller card assembly. Note: Remove the cable from the restraint, and observe the routing for reinstallation. 4. Remove the eight screws (A) securing the HCIT tray lift drive motor assembly. 5.
Page 489: High Capacity Input Tray (Hcit) Controller Card Assembly Removal
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. See “High capacity input tray (HCIT) cover, left removal” on page 4-164. 2.
Page 490: High Capacity Input Tray (Hcit) Media Size Actuator Assembly Removal
3. Remove the three screws (A) securing the HCIT controller card assembly. 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.
Page 491 4. Snap loose the actuator switch (C) and remove. 5. Remove the four screws (D) securing the media size actuator (E) and the card mount option (F) to the frame. 6. Remove the screw securing the media size actuator to the card mount option. 4-171 Repair information...
Page 492: Sensor (Hcit Tray Raised Hp) With Cable Assembly Removal
7. Remove the media size actuator from the card mount option. 8. Remove the card mount option. Sensor (HCIT tray raised HP) with cable assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164. 2.
Page 493: Sensor (Hcit Pass Through) With Cable Removal
5. Remove the sensor (HCIT tray raised HP). 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. See “High capacity input tray (HCIT) cover, left removal” on page 4-164. 4-173 Repair information...
Page 494 2. Disconnect the sensor (HCIT pass through) 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. 4. Remove the sensor (HCIT pass through) with cable from the top plate. 4-174 Service Manual...
Page 495: High Capacity Input Tray (Hcit) Pick Arm Bracket Assembly Removal
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. See “High capacity input tray (HCIT) cover, left removal” on page 4-164. 2.
Page 496 4. Remove the five screws (A) securing the HCIT pick arm bracket assembly. 5. Remove the HCIT pick arm bracket assembly from the drawer by slightly lifting and removing it. 4-176 Service Manual...
Page 497: High Capacity Input Tray (Hcit) Tray Closed Latch With Spring Removal
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.
Page 498 250-sheet media tray assembly removal Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly. 250-sheet option drawer assembly removal Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly. 4-178 Service Manual...
Page 499 250-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. 3.
Page 500: Sheet Media Out Actuator Removal
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. See “250-sheet pick arm bracket assembly removal” on page 4-179. 2. Release the hook (A) securing the 250-sheet media out actuator to the 250-sheet pick arm bracket assembly.
Page 501 250-sheet frame assembly removal Note: The 250-sheet frame assembly is not a FRU. 1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal” on page 4-179. 2. Release the hooks securing the sensor (pass through) to the drawer. 3.
Page 502 4. Remove the four screws (A) securing the 250-sheet frame assembly to the drawer. 5. Remove the 250-sheet frame assembly. 4-182 Service Manual...
Page 503 6. Disconnect the sensor (pass through) cable connector from the 250-sheet controller card. 7. Remove the sensor (pass through) with cable. 4-183 Repair information...
Page 504 250-sheet controller card assembly removal 1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal” on page 4-179. 2. Release the hooks securing the sensor (pass through) to the drawer. 3. Remove the sensor (pass through) from the drawer. 4.
Page 505 5. Remove the 250-sheet frame assembly. 6. Disconnect the three connectors from the 250-sheet controller card assembly. 7. Remove the three screws (B) securing the 250-sheet controller card assembly to the 250-sheet frame. 8. Remove the 250-sheet controller card assembly. 4-185 Repair information...
Page 506 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 4-184. 2. Remove the screw (A) securing the media size actuator to the 250-sheet frame. 3.
Page 507 Media tray catch spring removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal” on page 4-179. 2. Release the hooks securing the sensor (pass through) to the drawer. 3.
Page 508 6. Turn the drawer over so that you can access the media tray catch spring. 7. Release the media tray catch spring. Tray roller catch assembly removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1.
Page 509 2. Remove the tray roller catch assembly from the drawer. 4-189 Repair information...
Page 510 550-sheet option tray assembly 4-190 Service Manual...
Page 511 550-sheet media tray assembly removal Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly. 550-sheet option drawer assembly removal Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly. 4-191 Repair information...
Page 512 550-sheet pick arm bracket assembly removal 1. Remove the 550-sheet media tray assembly. See “550-sheet media tray assembly removal” on page 4-191. 2. Remove the two 550-sheet pick arm bracket assembly cable connectors (A) from the 550-sheet controller card assembly. 3.
Page 513: Sheet Bellcrank Recoil Spring Removal
550-sheet bellcrank recoil spring removal 1. Remove the 550-sheet pick arm bracket assembly. See “550-sheet pick arm bracket assembly removal” on page 4-192. 2. Remove the 550-sheet bellcrank recoil spring from the 550-sheet pick arm bracket assembly. Media out actuator removal (models T652 and T654) 1.
Page 514 Anti-tip latch assembly removal 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, but removing the right latch is similar. 1. Remove the 550-sheet media tray assembly. See “550-sheet media tray assembly removal” on page 4-191.
Page 515 550-sheet frame assembly removal Note: The 550-sheet frame assembly is not a FRU. 1. Remove the 550-sheet pick arm bracket assembly. See “550-sheet pick arm bracket assembly removal” on page 4-192. 2. Release the hooks securing the sensor (pass through) to the drawer. 3.
Page 516 5. Remove the 550-sheet frame assembly. 4-196 Service Manual...
Page 517: Upper Interface Cable Assembly Removal
Upper interface cable assembly removal 1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195. 2. Disconnect the upper interface cable connector (A) from the 550-sheet controller card. 3. Release the two hooks (B) securing the options auto connect to the 550-sheet frame. 4.
Page 518 Sensor (pass through) with cable removal 1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195. 2. Disconnect the sensor (pass through) cable connector from the 550-sheet controller card. 3. Remove the sensor (pass through) with cable. 550-sheet controller card assembly removal 1.
Page 519 3. Remove the three screws (A) securing the 550-sheet controller card assembly to the 550-sheet frame. 4. Remove the 550-sheet controller card assembly. 4-199 Repair information...
Page 520 Media size actuator removal 1. Remove the 550-sheet controller card assembly. See “550-sheet controller card assembly removal” on page 4-198. 2. Remove the screw (A) securing the media size actuator to the 550-sheet frame. 3. Remove the media size actuator. 4-200 Service Manual...
Page 521: Sheet Option Drive Shaft With Spring Removal
550-sheet option drive shaft with spring removal 1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195. 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. 4.
Page 522: Media Tray Roller Catch Assembly Removal
Media tray catch spring removal 1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195. 2. Turn the drawer over so that you can access the media tray catch spring. 3. Release the media tray catch spring. Media tray roller catch assembly removal 1.
Page 523: Mfp Stapler Assembly Rear Door Assembly Removal
MFP 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.
Page 524: Mfp Stapler Assembly Left Cover Removal
MFP stapler assembly left cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. 2. Pull out on the front side of the left cover to disengage the tabs. 3. Remove the left cover. MFP stapler assembly top cover removal 1.
Page 525: Mfp Stapler Assembly Handle Cover Removal
2. Remove the screw (A) on each side of the top cover. 3. Pull up and toward the front to remove the top cover. MFP stapler assembly handle cover removal 1. Remove the left and right cover. See “MFP stapler assembly left cover removal” on page 4-204 and “MFP stapler assembly right cover removal”...
Page 526: Mfp Stapler Assembly Led Sensor Cover Removal
2. Remove the two screws (A) on each side of the. 3. Lift up and to the rear to remove the cover. MFP stapler assembly LED sensor cover removal 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. 4-206 Service Manual...
Page 527 2. Remove the standard output bin LED. See “MFP stapler assembly standard output bin LED and LED clear lens removal” on page 4-208. 3. Remove the sensor (finisher media bin present). See “MFP stapler assembly sensor (finisher media bin present) removal” on page 4-208. 4.
Page 528: Mfp Stapler Assembly Sensor (Finisher Media Bin Present) Removal
MFP stapler assembly sensor (finisher media bin present) removal 1. Remove the LED sensor cover. See “MFP stapler assembly LED sensor cover removal” on page 4-206. 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. 3.
Page 529: Mfp Stapler Assembly Tamper Drive Belt Removal
2. Remove the two screws (A) securing the LED to the cover. 3. Remove the LED and disconnect the harness. 4. Remove the LED clear lens. MFP stapler assembly tamper drive belt removal 1. Remove the tamper recoil spring. See “MFP stapler assembly tamper drive belt removal” on page 4-209.
Page 530: Mfp Stapler Assembly Tamper Drive Motor Assembly Removal
MFP stapler assembly tamper drive motor assembly removal 1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204. 2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley. 3.
Page 531 4-211 Repair information...
Page 532: Mfp Stapler Assembly Stapler Unit Assembly Removal
MFP stapler assembly stapler unit assembly removal 1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203. 2. Remove the four cable harnesses attached to the stapler unit assembly. 3. Remove the three screws (A) securing the stapler unit assembly. 4.
Page 533 Stapler/stacker controller card assembly removal 1. Remove the left left cover. See “MFP stapler assembly left cover removal” on page 4-204. 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. 4.
Page 534 4. Remove the two screws (A) securing the two paddle drive motor assemblies. 5. Remove the paddle drive motor assembly. 4-214 Service Manual...
Page 535: Mfp Stapler Assembly Sensor (Paddle Hp) Removal
MFP stapler assembly sensor (media stack) removal 1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204. 2. Disconnect the harness to the sensor (media stack). 3. Using your fingers, pinch tab (A) securing the sensor (media stack) and remove. MFP stapler assembly sensor (paddle HP) removal 1.
Page 536: Mfp Stapler Assembly Sensor (Stapler Access Door Interlock) Removal
3. Using your fingers, pinch tab (A) securing the sensor (paddle home position) and remove. MFP stapler assembly sensor (stapler access door interlock) removal 1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203. 2. Disconnect the harness to the sensor (stapler access door interlock). 3.
Page 537: Mfp Stapler Assembly Sensor (Bin Full Send) Removal
MFP stapler assembly sensor (tamper HP left and right) removal 1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204. 2. Disconnect the harness to the 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 538: Mfp Stapler Assembly Sensor (Bin Full Receive) Removal
2. Remove the two screws (A) securing the staple finisher sensor (bin full send). 3. Disconnect the harness and remove. MFP stapler assembly sensor (bin full receive) removal 1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203. 2.
Page 539: Mfp Stapler Assembly Sensor (Media In Stapler) Removal
MFP stapler assembly sensor (media in stapler) removal 1. Remove the stapler unit assembly from the . See “MFP stapler assembly stapler unit assembly removal” on page 4-212. 2. Using a flat-blade screwdriver, release the tabs (A) securing the sensor. 3.
Page 540: Mfp Stapler Assembly Sensor (Deflector Hp) Removal
MFP stapler assembly sensor (deflector HP) removal 1. Remove the left cover. See “MFP stapler assembly left cover removal” on page 4-204. 2. Disconnect the harness to the sensor (deflector HP). 3. Release the tabs (A) securing the sensor to the unit. Note: The tabs may be difficult to access.
Page 541: Bin Mailbox Assembly Left Cover Removal
4-bin mailbox assembly left cover removal 1. Place the 4-bin mailbox assembly on its side. 2. Remove the two screws (A) on the underside of the 4-bin mailbox assembly securing the left cover. 3. Using your finger, pull up on the top surface of the left cover while simultaneously pulling out, and remove. 4-bin mailbox assembly controller card assembly removal 1.
Page 542: Bin Mailbox Assembly Sensor (Media Bin Full) Removal
3. Remove the two screws (A) securing the controller card to the 4-bin mailbox assembly and remove. 4-bin mailbox assembly sensor (media bin full) removal 1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on page 4-221.
Page 543: Bin Mailbox Assembly Sensor (Deflector Gate Hp) Removal
3. Pinch the tabs securing the sensor (media bin full) to the media tray and remove. 4-bin mailbox assembly sensor (deflector gate HP) removal 1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on page 4-221.
Page 544: Bin Mailbox Assembly Rear Door Assembly Removal
4-bin mailbox assembly rear door assembly removal 1. Open the rear door. 2. Gently spread each side of the 4-bin mailbox assembly until the rear door hinge is free to be removed. 3. Remove the rear door assembly. 4-224 Service Manual...
Page 545: Bin Mailbox Assembly Right Cover Removal
4-bin mailbox assembly right cover removal 1. Place the 4-bin mailbox assembly on its side. 2. Remove the two screws (A) from the bottom side of the right cover securing cover in place. 3. Using your fingers, pull up on the top of the right cover and pull out simultaneously to remove. 4-bin mailbox assembly LED card assembly removal 1.
Page 546: Bin Mailbox Assembly Top Cover Removal
3. Remove the three screws (A) securing the LED card assembly to the 4-bin mailbox assembly. 4. Remove the 4-bin mailbox assembly LED card assembly. 4-bin mailbox assembly top cover removal 1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on page 4-221.
Page 547: Bin Mailbox Assembly Deflector Gate Solenoid Removal
4. Slide the top cover towards the rear and remove. 4-bin mailbox assembly deflector gate solenoid removal 1. Remove the 4-bin mailbox assembly top cover. See “4-bin mailbox assembly top cover removal” on page 4-226. 2. Remove the screw (A) securing the deflector gate solenoid to the 4-bin mailbox assembly. 3.
Page 548: Bin Mailbox Assembly Transport Solenoid Removal
4-bin mailbox assembly transport solenoid removal 1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on page 4-221. 2. Remove the left rear inner cover. 3. Disconnect the transport solenoid cable from the controller card. 4.
Page 549: Bin Mailbox Assembly Spring Removal
4-bin mailbox assembly spring removal 1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door assembly removal” on page 4-224. 2. Using a spring hook or needlenose pliers, remove the spring off the hooks. 4-229 Repair information...
Page 550: Bin Mailbox Assembly Deflector Gate (Bin 1 Through 3) Removal
4-bin mailbox assembly deflector gate (bin 1 through 3) removal 1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door assembly removal” on page 4-224. 2. Remove the 4-bin mailbox assembly right rear inner cover. 3.
Page 551: Bin Mailbox Assembly Deflector Gate (Bin 4) Removal
4-bin mailbox assembly deflector gate (bin 4) removal 1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door assembly removal” on page 4-224. 2. Grasp the 4th bin deflector gate and pull out on either side. 4-231 Repair information...
Page 552: Bin Mailbox Assembly Sensor (Pass Through) Removal
4-bin mailbox assembly sensor (pass through) removal Note: The sensor (pass through) is the lower rear sensor. The rear upper sensor is the sensor (mailbox empty). 1. Open the rear door. 2. Lift the deflector gate above the sensor (pass through) and using a flat-blade screwdriver, release the tabs securing the sensor (pass through) to the 4-bin mailbox assembly.
Page 553: Bin Mailbox Assembly Sensor (Mailbox Empty) Removal
4-bin mailbox assembly sensor (mailbox empty) removal Note: The sensor (pass through) is the lower rear sensor. The rear upper sensor is the sensor (mailbox empty). 1. Open the rear door. 2. Lift the deflector gate above the sensor (mailbox empty) and using a flat-blade screwdriver, release the tabs securing the sensor (mailbox empty) to the 4-bin mailbox assembly.
Page 554: Bin Mailbox Assembly Standard Output Bin Led Removal
4-bin mailbox assembly standard output bin LED removal 1. Remove the three screws (A) on the underside of bin 1 securing the output bin LED bracket. 2. Pull the output bin LED bracket out from the underside of bin 1 and disconnect the LED harness. 4-234 Service Manual...
Page 555 3. Remove the two screws (B) securing the output bin LED to the bracket and remove the output bin LED. 4-235 Repair information...
Page 556: Bin Mailbox Assembly Led Clear Lens Removal
4-bin mailbox assembly LED clear lens removal 1. Remove the 4-bin mailbox standard output bin LED. See “4-bin mailbox assembly sensor (mailbox empty) removal” on page 4-233. 2. Remove the output bin LED clear lens from the output bin LED bracket. 4-bin mailbox assembly media bin full actuator removal 1.
Page 557: Offset Stacker Rear Door Assembly Removal
3. Pull the media bin full actuator toward the front and out of 4-bin mailbox assembly. Offset stacker 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.
Page 558: Offset Stacker Left Cover Removal
Offset stacker left cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. 2. Pull out on the front side of the left cover to disengage the tabs. 3. Remove the offset stacker left cover. Offset stacker top cover removal 1.
Page 559: Offset Stacker Handle Cover Removal
2. Remove the screw (A) on each side of the top cover. 3. Pull up and toward the front to remove the offset stacker top cover. Offset stacker handle cover removal 1. Remove the left and right cover. See “Offset stacker left cover removal” on page 4-238 and “Offset stacker right cover removal”...
Page 560: Offset Stacker Led Sensor Cover Removal
2. Remove the two screws (A) on each side of the offset stacker. 3. Lift up and to the rear to remove the cover. Offset stacker LED sensor cover removal 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. 4-240 Service Manual...
Page 561 2. Remove the offset stacker standard output bin LED. See “Offset stacker standard output bin LED and LED clear lens removal” on page 4-242. 3. Remove the sensor (finisher media bin present). See “Offset stacker sensor (finisher media bin present) removal” on page 4-242. 4.
Page 562: Offset Stacker Sensor (Finisher Media Bin Present) Removal
Offset stacker sensor (finisher media bin present) removal 1. Remove the offset stacker LED sensor cover. See “Offset stacker LED sensor cover removal” on page 4-240. 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. 3.
Page 563: Offset Stacker Tamper Drive Belt Removal
2. Remove the two screws (A) securing the LED to the cover. 3. Remove the LED and disconnect the harness. 4. Remove the LED clear lens. Offset stacker tamper drive belt removal 1. Remove the offset stacker tamper recoil spring. See “Offset stacker tamper drive belt removal” on page 4-243.
Page 564: Offset Stacker Tamper Drive Motor Assembly Removal
Offset stacker tamper drive motor assembly removal 1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238. 2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley. 3.
Page 565 4-245 Repair information...
Page 566: Offset Stacker Paddle Drive Motor Assembly Removal
Stapler/stacker controller card assembly removal 1. Remove the left left cover. See “Offset stacker left cover removal” on page 4-238. 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. 4.
Page 567: Offset Stacker Sensor (Media Stack) Removal
4. Remove the two screws (A) securing the two paddle drive motor assemblies. 5. Remove the paddle drive motor assembly. Offset stacker sensor (media stack) removal 1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238. 2.
Page 568: Offset Stacker Sensor (Paddle Hp) Removal
3. Using your fingers, pinch tab (A) securing the offset stacker sensor (media stack) and remove. Offset stacker sensor (paddle HP) removal 1. Remove the offset stacker left cover. See “Offset stacker left cover removal” on page 4-238. 2. Disconnect the harness to the offset stacker sensor (paddle home position). 3.
Page 569: Offset Stacker Sensor (Bin Full Send) Removal
Offset stacker sensor (tamper HP left and right) removal 1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238. 2. Disconnect the harness to the offset stacker sensor (tamper HP left and right). 3. Using your fingers, pinch the tabs securing the staple finisher sensor (tamper HP left and right) and remove. Offset stacker sensor (bin full send) removal 1.
Page 570: Offset Stacker Sensor (Bin Full Receive) Removal
2. Remove the two screws (A) securing the staple finisher sensor (bin full send). 3. Disconnect the harness and remove. Offset stacker sensor (bin full receive) removal 1. Remove the offset stacker right cover. See “Offset stacker right cover removal” on page 4-237. 2.
Page 571: Offset Stacker Sensor (Deflector Hp) Removal
Offset stacker sensor (deflector HP) removal 1. Remove the offset stacker left cover. See “Offset stacker left cover removal” on page 4-238. 2. Disconnect the harness to the sensor (deflector HP). 3. Release the tabs securing the sensor to the offset stacker. Note: The tabs may be difficult to access.
Page 572 4-252 Service Manual...
Page 573: Connector Locations
5. Connector locations Locations Sensors–ADF Sensor (ADF media length) Sensor (Media exit) Sensor (ADF media width) Sensor (ADF document set) Sensor (ADF lower door interlock) ADF pick solenoid Switch (ADF closed interlock) Sensor (ADF rear registration) Sensor (ADF front registration) Sensor (ADF top door interlock) Sensor (ADF sheet through)
Page 574 Service Manual...
Page 575: Preventive Maintenance
6. Preventive maintenance This chapter describes procedures for printer preventive maintenance. Follow these recommendations to 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 576: Scheduled Maintenance
Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval. 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. The parts are available as a maintenance kit with the following part numbers: Maintenance kits Maintenance...
Page 577: Cleaning The Scanner Glass
Cleaning the scanner glass Clean the scanner glass if you encounter print quality problems, such as streaks on copied or scanned images. Slightly dampen a soft, lint-free cloth or paper towel with water. Open the scanner cover. Wipe the scanner glass until it is clean and dry. Wipe the white underside of the scanner cover until it is clean and dry.
Page 578 Close the scanner cover. Note: Dell recommends the use of Klear Screen cleaner for the scanner glass, LCD screen, and operator panel buttons. This can be ordered from www.KlearScreen.com or by calling 1-800-505=5327. Order kit(s) KS- SP12 or KS-SP50. Warning: Dell does not recommend the use of any alcohol based solution on the operator panel buttons or the LCD screen as cosmetic damage to those assemblies may result.
Page 579: Parts Catalog
PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet. • Model information used in the parts catalog: Machine Description type Simplex Duplex Duplex Modem Hard drive printer 7462-031 X651de 7462-035 X652de/ 5535dn 7462-0A1 X654de 7462-0A5 X656dte 7462-231 X654de 7462-232 X654de 7462-235 X656dte 7462-236 X656dte 7462-2A1 X654de 7462-2A2...
Page 580 Assembly 1: Covers (X651, X652/5535dn, X654, and X656) Service Manual...
Page 581 Assembly 1: Covers (X651, X652/5535dn, X654, and X656) Asm- Part Units/ Units/ Description index number option 40X2169 Scanner cover plug, rear (X651) 40X4506 Scanner cover, rear 40X4508 Scanner cover, right (X651, X652, X654, and X656) 40X4509 Scanner support platform (X651, X652, X654, and X656)
Page 582 Assembly 2: Covers 1 (X658) Service Manual...
Page 583 Assembly 2: Covers 1 (X658) Asm- Part Units/ Units/ Description index number option 40X1970 Laser cover assembly, 550 sheet (X658) 40X4480 Output cover assembly (X658) 40X4331 Door assembly, rear 40X4470 Output bail 40X4335 Cover assembly, rear lower 40X4477 Corner cover, left rear (X658) 40X4479 Corner cover, right rear (X658) 40X4478...
Page 584 Assembly 3: Covers 2 (X658) Service Manual...
Page 585 Assembly 3: Covers 2 (X658) Asm- Part Units/ Units/ Description index number option 40X4510 Scanner cover, rear (X658) 40X4511 Scanner cover, right (X658) 40X4513 Scanner cover, front (X658) 40X4516 Scanner support cover, left rear (X658) 40X4520 Scanner support inner cover, right (X658) 40X4517 Scanner support cover, right (X658) 40X4518...
Page 586 Assembly 4: Media path and ducts Service Manual...
Page 587 Assembly 4: Media path and ducts Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4384 EP cooling fan duct 40X1868 Print cartridge clamp assembly 40X4390 Machine pad 40X1869 Transfer deflector with static brush 40X1900 Media turn guide with actuator 40X4388 Inner deflector 40X4406...
Page 588 Assembly 5: Pick arm and media tray assemblies 7-10 Service Manual...
Page 589: Assembly 5: Pick Arm And Media Tray Assemblies
Assembly 5: Pick arm and media tray assemblies Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4459 MPF lift plate assembly (X651, X652, X654, and X656) 40X4425 MPF lift plate assembly with spring (X658) 40X4365 MPF pick solenoid assembly 40X1883 MPF pick roll assembly with flange and clip 40X4457...
Page 590 Assembly 6: Drive motor assembly, redrive, and duplex 7-12 Service Manual...
Page 591 Assembly 6: Drive motor assembly, redrive, and duplex Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4467 Redrive assembly 40X5851 Duplex drive motor assembly 40X4346 Duplex assembly with 2 belts and 2 pulleys 40X4351 Duplex guide handle 40X4352 Duplex guide, rear 40X4353...
Page 592 Assembly 7: Printhead, charge, and transfer assembly 7-14 Service Manual...
Page 593 Assembly 7: Printhead, charge, and transfer assembly Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4464 Printhead with cable assembly 40X1865 Printhead cable assembly 40X4317 Charge roll link spring, right 40X1888 Transfer roll bracket assembly, right 40X1886 Transfer roll assembly with tool 40X1887 Transfer roll bracket with cable assembly, left...
Page 594 Assembly 8: System card, HVPS and scanner controller card assemblies X658 only 7-16 Service Manual...
Page 595: Assembly 8: System Card, Hvps And Scanner Controller Card Assemblies
Assembly 8: System card, HVPS and scanner controller card assemblies Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4383 Cleaning blade contact 40X4381 Drum grounding contact 40X4382 Print cartridge HV contact 40X4370 Sensor (toner empty) 40X4362 HVPS card assembly 40X4361 HVPS / sensor cable assembly 40X4368...
Page 596 Assembly 9: Fuser and LVPS card assemblies 7-18 Service Manual...
Page 597: Assembly 9: Fuser And Lvps Card Assemblies
Assembly 9: Fuser and LVPS card assemblies Asm- Part Units/ Units/ Description index number option 40X1870 Fuser assembly 100V, type 1 40X4418 Fuser assembly 110V, type 1 40X1871 Fuser assembly 220V, type 1 40X5853 Fuser assembly 100V, type 2 40X5854 Fuser assembly 110V, type 2 40X5855 Fuser assembly 220V, type 2...
Page 598 Assembly 10: Flatbed scanner 7-20 Service Manual...
Page 599 Assembly 10: Flatbed scanner Asm- Part Units/ Units/ Description index number option 40X2165 Scanner unit assembly (X651, X652, X654, and X656) 40X2166 Scanner unit assembly (X658) 40X2642 Scanner platen glass cover assembly 40X4530 Scanner FB length sensor cable assembly 40X4527 Scanner exposure lamp 40X4526 Scanner CCD assembly...
Page 600 Assembly 11: ADF unit assembly 7-22 Service Manual...
Page 601 Assembly 11: ADF unit assembly Asm- Part Units/ Units/ Description index number option 40X2738 ADF unit assembly (X651 and X652) 40X2745 ADF unit assembly (X654, X656, and X658) 7-23 Parts catalog...
Page 602 Assembly 12: ADF covers 7-24 Service Manual...
Page 603 Assembly 12: ADF covers Asm- Part Units/ Units/ Description index number option 40X4537 ADF top door assembly 40X3439 Left hinge assembly 40X2746 ADF cover cap, rear left (X651 and X652) 40X4563 Right hinge assembly 40X4539 ADF cover, rear 40X4564 Document tray extension 40X3444 ADF platen cushion 40X3392...
Page 604 Assembly 13: ADF feed and drive 7-26 Service Manual...
Page 605 Assembly 13: ADF feed and drive Asm- Part Units/ Units/ Description index number option 40X4540 ADF feed / pick roll assembly 40X4545 Spring 40X7213 Feed motor assembly with belt and cable 40X4544 Transport motor bracket assembly with cable 40X2759 Transport drive gear and pulley kit, rear 40X2749 Feed one-way bearing and gear kit 40X4542...
Page 606 Assembly 14: ADF electronics 7-28 Service Manual...
Page 607 Assembly 14: ADF electronics Asm- Part Units/ Units/ Description index number option 40X6398 Spacer 40X4561 ADF document tray assembly 40X4559 ADF tray length cable assembly 40X4558 ADF sensor cable assembly 1 40X4606 Sensor (ADF media exit) bracket assembly (X651 and X652) 40X4607 Sensor (ADF media exit) bracket assembly with fan (X654, X656, and X658)
Page 608 Assembly 15: 550 Sheet option tray assembly (X658) 7-30 Service Manual...
Page 609: Assembly 15: 550 Sheet Option Tray Assembly (X)
Assembly 15: 550 Sheet option tray assembly (X658) Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X3967 Complete 550 sheet option tray assembly (X658) 40X3454 550 Sheet pick arm bracket assembly 40X4307 550 Sheet bellcrank recoil spring 40X4308 Pick roll assembly (2) 40X4369...
Page 610 Assembly 16: 250 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) 7-32 Service Manual...
Page 611 Assembly 16: 250 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4569 Complete 250 sheet option tray assembly 40X3447 250 Sheet pick arm bracket assembly 40X3448 250 Sheet bellcrank recoil spring...
Page 612 Assembly 17: 550 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) 7-34 Service Manual...
Page 613: Assembly 17: 550 Sheet Option Tray Assembly (X651, X652/5535Dn, X654, And X)
Assembly 17: 550 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4576 Complete 550 sheet option tray assembly 40X3454 550 Sheet pick arm bracket assembly 40X4307 550 Sheet bellcrank recoil spring...
Page 614 Assembly 18: HCIT Sheet option tray assembly (X651, X652/5535dn, X654, and X656) 7-36 Service Manual...
Page 615 Assembly 18: HCIT Sheet option tray assembly (X651, X652/5535dn, X654, and X656) Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4579 Complete HCIT option tray assembly 40X4590 HCIT pick arm bracket assembly 40X4595 Pick arm sensor cable assembly...
Page 616: Assembly 19: Mfp Stapler Assembly
Assembly 19: MFP stapler assembly 7-38 Service Manual...
Page 617 Assembly 19: MFP stapler assembly #1 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X7026 MFP stapler assembly (comes completely assembled) 7-39 Parts catalog...
Page 618 Assembly 20: MFP stapler assembly #2 7-40 Service Manual...
Page 619 Assembly 20: MFP stapler assembly #2 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4612 Handle cover 40X4613 Rear door assembly 40X4730 Stapler cover 40X4764 Hollow cover 40X4610 Right cover 40X5544 Sensor (bin full receive) 40X4617 Finisher bin spring 40X5545 Standard output bin LED 40X5727...
Page 620 Assembly 21: MFP stapler assembly #3 7-42 Service Manual...
Page 621 Assembly 21: MFP stapler assembly #3 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4645 Media stack flap actuator 40X4646 Media stack flap 40X4369 Sensor (media stack) 40X4621 Left tamper motor assembly 40X4622 Right tamper motor assembly 40X4624 Tamper recoil spring 40X4369...
Page 622 Assembly 22: MFP stapler assembly #4 7-44 Service Manual...
Page 623 Assembly 22: MFP stapler assembly #4 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4641 Stapler assembly 40X5909 Sensor (media in stapler) 7-45 Parts catalog...
Page 624 Assembly 23: MFP offset stacker assembly #1 7-46 Service Manual...
Page 625 Assembly 23: MFP offset stacker assembly #1 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X7025 MFP offset stacker assembly (comes completely assembled) 7-47 Parts catalog...
Page 626 Assembly 24: MFP Offset stacker #2 7-48 Service Manual...
Page 627 Assembly 24: MFP Offset stacker #2 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4612 Handle cover 40X4613 Rear door assembly 40X4730 Stapler cover 40X4610 Right cover 40X5544 Sensor (bin full receive) 40X4617 Finisher bin spring 40X5545 Standard output bin LED 40X5727 LED clear lens...
Page 628 Assembly 25: MFP Offset stacker #3 7-50 Service Manual...
Page 629 Assembly 25: MFP Offset stacker #3 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4645 Media stack flap actuator 40X4646 Media stack flap 40X4369 Sensor (media stack) 40X4621 Left tamper motor assembly 40X4622 Right tamper motor assembly 40X4624 Tamper recoil spring 40X4369...
Page 630 Assembly 26: MFP 4-bin mailbox assembly #1 7-52 Service Manual...
Page 631 Assembly 26: MFP 4-bin mailbox assembly #1 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X7024 MFP 4 bin mailbox assembly (comes completely assembled) 7-53 Parts catalog...
Page 632 Assembly 27: MFP 4-bin mailbox assembly #2 7-54 Service Manual...
Page 633 Assembly 27: MFP 4-bin mailbox assembly #2 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4644 Top media bin bail 40X4642 Top cover 40X4135 1st - 3rd media bail 40X4640 Left cover 40X4638 Left rear inner cover 40X4369 Sensor (deflector gate HP) 40X4632...
Page 634 Assembly 28: MFP 4-bin mailbox assembly #3 7-56 Service Manual...
Page 635 Assembly 28: MFP 4-bin mailbox assembly #3 Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5750 Spring 40X5728 Sensor (pass through) 40X4635 Deflector gate solenoid 40X5751 Attach roller 40X5545 Standard output bin LED 40X5727 LED clear lens 40X4647 Output bin LED bracket 40X4136...
Page 636 Assembly 29: Envelope feeder 7-58 Service Manual...
Page 637 Assembly 29: Envelope feeder Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5739 Envelope feeder (X658 only) 7-59 Parts catalog...
Page 638: Assembly 30: Miscellaneous
Assembly 30: Miscellaneous Asm- Part Units/ Units/ kit Description Index number mach or pkg 7372935 Relocation kit (X651, X652, and X654) 7377730 Relocation kit (X658) 40X4723 Printer maintenance kit (100 V type 1 fuser) 40X4724 Printer maintenance kit (110 V type 1 fuser) 40X4765 Printer maintenance kit (220 V type 1 fuser) 40X4766...
Page 639 Assembly 30 (continued): Miscellaneous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X1462 Locking universal media drawer with tray, 200 sheet (excluding X658) 40X1463 Locking media drawer with tray, 550 sheet (excluding X658) 40X1464 Locking universal media drawer with tray, 400 sheet (excluding X658) 7-61 Parts catalog...
Page 640: Assembly 31: Power Cords
Assembly 31: Power cords Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X0269 Power cord LV, USA & Canada, Latin America 40X0288 Power cord HV, Argentina 40X0273 Power cord HV, Chile, Uruguay 40X3141 Power cord HV, Paraguay, Austria, Belgium, France, Germany, Italy, Netherlands, Bluemark, Czech &...
Page 641: Assembly 32: Universal Trays And Accessories
Assembly 32: Universal trays and accessories Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5857 Universal media drawer with tray, 200 sheet (X651, X652, X654, and X656) 40X5858 Universal media tray, 200 sheet (X651, X652, X654, and X656) 40X5859 Universal media drawer with tray, 400 sheet (X651, X652, X654, and X656) 40X5860...
Page 642 7-64 Service Manual...
Page 643 Index diagnostics 2-11 error code table acronyms diagnostics menu ADF & scanner image quality accessing 2-173 dark image quality available tests adjustments 3-20 BASE SENSOR TEST fuser solenoid DEVICE TESTS gap adjustment 3-21 Disk Test/Clean 3-27 ASIC Test 3-21 Quick Disk Test DUPLEX TESTS 3-18 3-14...
Page 644 2-169 2-178 SCANNER TESTS media damage 3-27 2-171 ASIC Test no fuse 3-27 2-163 Feed Test partial lack 3-27 2-168 2-177 Sensor Tests skew 3-38 2-164 2-175 Disk Encryption spots 3-15 2-160 2-174 DRAM Test vertical stripes 3-82 3-19 Duplex input sensor tray tests 3-12 duplex tests...
Page 645 3-99 print skew correction printer overview 3-77 tools 3-43 printer theory Top Margin 3-61 control 3-17 duplex 3-61 fuser control 3-11 simplex (front side) 3-61 printhead control 3-68 document scanning 3-68 document scanning at platen 3-77 unique tools 3-58 drive 3-59 electrical components and controller 3-24...
Page 646 Service Manual...
Page 647: Part Number Index
40X1919 Output cover assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 40X1970...
Page 648 Spring connector (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 649 40X4377 USB cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 650 Scanner cover, left (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 651 40X4521 Carriage drive motor assembly with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21 40X4522 Carriage belt tensioner assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 652 ADF separator roll and guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27 40X4606 Sensor (ADF media exit) bracket assembly (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - 7-29 40X4607...
Page 653 550 Sheet option drawer assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31 40X5848 Envelope / input option cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - 7-17 40X5850...
Page 654 Relocation kit (X651, X652/5535dn, and X654) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
Page 655 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.

Dell 5535dn Service Manual

Table of Contents

Notices and Safety Information

Preface

General Information

Diagnostic Information

Diagnostic Aids

B

100 C

Q

500 D

R

Repair Information

Quick Links

Troubleshooting

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Summary of Contents for Dell 5535dn