Lexmark T650 Service Manual
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Lexmark T650 Service Manual

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Download this manual See also: Troubleshooting Manual, Administrator's Manual
Edition: September 27, 2012
™
Lexmark
T650, T650n, T652dn,
T654dn & T656dne Printer
4062-XXX
• Table of contents
• Start diagnostics
• Safety and notices
• Trademarks
• Index
Lexmark and Lexmark with diamond design are
trademarks of Lexmark International, Inc., registered
in the United States and/or other countries.

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Summary of Contents for Lexmark T650

  • Page 1 T654dn & T656dne Printer 4062-XXX • Table of contents • Start diagnostics • Safety and notices • Trademarks • Index Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
  • Page 2 Lexmark, Lexmark with diamond design, and MarkNet are trademarks of Lexmark International, Inc., registered in the United States and/or other countries. PCL® is a registered trademark of the Hewlett-Packard Company.

  • Page 3: Table Of Contents

    4062-XXX Table of contents Previous Table of contents ............iii Notices and safety information .
  • Page 4 Exiting Diagnostics mode (models T650, T652, and T654) ....... 3-5...
  • Page 5 EXIT DIAGNOSTICS (models T650, T652, and T654) ........
  • Page 6 Exit Config Menu (models T650, T652, and T654) ....... . .
  • Page 7 Model T650 with duplex, paper path, rolls, and sensors .......
  • Page 8 Model T650 paper path, rolls, and sensors ........
  • Page 9 Connection bezel assembly, rear removal (T650) ........
  • Page 10 MPF tray door assembly removal (T650, T652, T654) ........4-40 Operator panel latch assembly removal (T650, T652, T654) ......4-42 Operator panel door assembly removal (T650, T652, T654) .
  • Page 11 4062-XXX Transfer roll assembly removal ........... 4-80 Previous Transfer roll bracket assembly, left removal .
  • Page 12 4062-XXX High capacity stacker right frame removal .........4-142 Previous High capacity stacker left frame removal .
  • Page 13 ............. . 7-2 Assembly 2: T650, T652, and T654 Operator panel .
  • Page 14 4062-XXX Previous Next Go Back Service Manual...

  • Page 15: Notices And Safety Information

    4062-XXX Notices and safety information Previous The following laser notice labels may be affixed to this printer. Next Laser notice Go Back 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 4062-XXX Previous 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 Next Clase I (1).
  • Page 17 4062-XXX Previous 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. Next 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 4062-XXX Previous 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 4062-XXX Previous Next Go Back Notices and safety information...
  • Page 20 4062-XXX Previous Next Go Back Service Manual...

  • Page 21: Lithium Warning

    4062-XXX Previous Lithium warning CAUTION This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY Next IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery manufacturer’s instructions and local regulations. Go Back Safety information •...
  • Page 22 4062-XXX Previous 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. Next • Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen Wartungsfachmann bestimmt.
  • Page 23 4062-XXX Previous 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 Next seguretat si s'utilitzen peces de recanvi no autoritzades. •...

  • Page 24: Go Back

    4062-XXX Preface Previous 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 Next repair it. Special tools and test equipment, as well as general environmental and safety instructions, are discussed.

  • Page 25: Change History

    • Updated the art for “550 Sheet option tray assembly” on page 7-22. 2011/7/11 Replaced PN 40X4309 with PN 40X1384 for the 250 sheet media out actuator (T650) in“Pick arm assembly, trays, and MPF” on page 7-15. 2011/7/08 Replaced PN 40X4309 with PN 40X5840 in “250 Sheet option tray assembly”...

  • Page 26: Conventions

    4062-XXX Previous Conventions Note: A note provides additional information. Warning: A warning identifies something that might damage the product hardware or software. Next There are several types of caution statements: CAUTION Go Back A caution identifies something that might cause a servicer harm. CAUTION This type of caution indicates there is a danger from hazardous voltage in the area of the product where you are working.

  • Page 27: General Information

    4062-XXX 1. General information Previous The Lexmark™ laser printers are letter-quality page printers designed to attach to personal computers and to most computer networks. The Lexmark laser printers are available in the following models: Next Machine type Model Configuration Go Back...

  • Page 28: Options

    – IPDS and SCS/TNe – PrintCryption – PRESCRIBE • Printer hard disk • Lexmark™ Internal Solutions Ports (ISP) – RS-232-C serial interface ISP – Parallel 1284-B interface ISP – MarkNet N8150 802.11 b/g/n Wireless ISP – MarkNet N8130 10/100 Thick Fiber ISP –...

  • Page 29: Printer Configurations

    4062-XXX Printer configurations Previous Basic model The following illustration shows the basic printer model. Next Go Back Feature Paper Capacity Standard exit bin 250- or 550-sheet Printer control panel Multipurpose feeder 100 sheets Standard tray (Tray 1) 250- or 550-sheets Based on 75 g/m (20 lb.) paper.

  • Page 30: Fully Configured Model

    You must use either a printer stand or printer base if you are using a 2000-sheet tray, a duplex unit, and an input option, or more than one input option. Next For more information, see www.lexmark.com/publications/furniture_safety. Go Back Service Manual...
  • Page 31 The printer supports up to three output expander units, or one output expander combined with one 5- bin mailbox, one high capacity output expander (not depicted), or one stapler unit (not depicted). Optional external duplex unit for the T650 model. All other models are available with or without internal duplex unit.

  • Page 32: Supported Paper Sizes, Types, And Weights

    4062-XXX Supported paper sizes, types, and weights Previous 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. Next Paper sizes supported by the printer Go Back 250-or 550-sheet Optional...

  • Page 33: Paper Types And Weights Supported By The Printer

    4062-XXX Previous 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 Next (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 34: Tools Required

    4062-XXX The finisher supports 60-176 g/m2 (16-47 lb) paper weights. Previous Optional hardware Output Expander (550 Standard exit bin StapleSmart II Paper type Next sheets) or High 5-Bin Mailbox (350 or 550 sheets) Finisher Capacity (500 sheets) (500 sheets) Output stacker Go Back (1850 sheets) Paper...

  • Page 35: Acronyms

    4062-XXX Previous Acronyms BLDC Brushless DC motor Customer Replaceable Unit Next Customer setup DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory Go Back Digital multimeter Enhanced Data Out EEPROM Electrically Erasable Programable Read-Only Memory Electrophotographic process EPROM Erasable Programmable Read-Only Memory Electrostatic Discharge Field Replaceable Unit Gigabyte...
  • Page 36 4062-XXX Previous Next Go Back 1-10 Service Manual...

  • Page 37: Diagnostic Information

    4062 2. Diagnostic information Previous Start Next CAUTION: Unplug the power cord from the electrical outlet before you connect or disconnect any cable or Go Back 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 38: Confirm The Installation Status

    The following is an example of the events that occur during the POR sequence: 1. Turn the machine on. 2. The Lexmark splash screen appears with a progress bar in the center until the code is loaded. 3. The fuser cooling fan turns on.

  • Page 39: User Attendance Messages

    4062 Previous User attendance messages Error code or Error contents Description/Action Possible repair actions Next 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 Go Back responding.
  • Page 40 4062 Previous 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 Next to enable Resource Save. This memory to enable Resource message usually indicates the Save.
  • Page 41 4062 Previous 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: Next restore the Print and Hold jobs from the disk and found that •...
  • Page 42 4062 Previous Error code or Error contents Description/Action Possible repair actions message 44.01 RFID Error Bad tag error: a tag has failed 1. Retest using new RFID to program, or the “Retry media. Next Count” has been exceeded. 2. Check the RFID firmware card, RFID interface card, Note: This error is not a data RFID cable, and RFID...
  • Page 43 4062 Previous Error code or Error contents Description/Action Possible repair actions message 44.26 RFID Error Based on tag location 1. These error codes most parameters: tag is not likely indicate a problem Next compatible with printer with the customer’s datastream, and not the 44.27 RFID Error Unsupported SA Code...
  • Page 44 4062 Previous Error code or Error contents Description/Action Possible repair actions message 44.36 RFID Error Invalid X/Y Position 1. This error code most likely indicates a problem with Next the customer’s datastream, and not the RFID Option itself. Ensure there is Go Back nothing wrong with the customer’s datastream.
  • Page 45 4062 Previous Error code or Error contents Description/Action Possible repair actions message Flash Full This message displays when Press to clear the the printer detects an message. The flash is marked Next unformatted flash at power on. as bad and normal operation continues.
  • Page 46 4062 Previous Error code or Error contents Description/Action Possible repair actions message Serial Port [x] This error displays when data Go to network service check. Disabled is sent to the printer across an Next “Network service check” serial port, but the port has on page 2-170.

  • Page 47: Connections

    4062 Previous Error code or Error contents Description/Action Possible repair actions message Too Many Disks This error code displays when 1. Turn off and unplug the Installed too many disks are attached to printer. Next the printer. 2. Remove the excess disks. 3.
  • Page 48 4062 Previous Error code or Error contents Description/Action Possible repair actions message Incompatible Output An incompatible output bin is 1. Turn off and unplug the Bin [x] installed. For Output Bin x, x=1, printer. Next 2, or 3. 2. Remove the incompatible output option.
  • Page 49 4062 Previous Error code or Error contents Description/Action Possible repair actions message Cartridge Low This IR is displayed when Replace the print cartridge. cartridge low occurs and the Next cartridge low alarm is activated. If cartridge alarm is not activated, this is not an intervention condition.

  • Page 50: Error Code Table 1

    4062 Previous Error code table Error code or Error contents Description/Action Possible repair actions Next message 200.00 Sensor (input) area The media is jammed in the 1. Fan the media and check for sensor (input) area. obstructions. Go Back 2. Go to sensor (input) service check.
  • Page 51 3. Check all connections on the system card assembly. Go Back 4. Replace the printhead if problem remains. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. 200.10...
  • Page 52 3. Check all connections on the system card assembly. 4. Replace the printhead if problem remains. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60 5. Replace the system card if problem remains.
  • Page 53 4062 Previous Error code or Error contents Description/Action Possible repair actions message 200.27 Sensor (input) The media reached the sensor Go to sensor (input) lingering lingering jam (input) but did not clear it within jam service check. Next the specified time. Source = Tray 2 “Sensor (input) lingering Tray level = Not Low...
  • Page 54 4062 Previous Error code or Error contents Description/Action Possible repair actions message 200.39 Sensor (input) The media reached the sensor Go to sensor (input) lingering lingering jam (input) but did not clear it within jam service check. Next the specified time. Source = Tray 3 “Sensor (input) lingering Tray level = Empty...
  • Page 55 4062 Previous Error code or Error contents Description/Action Possible repair actions message 201.02 Sensor (fuser output) The media is late reaching the Go to sensor (fuser output) late late jam. sensor (fuser output) within the jam service check. Next specified time. Type 1 fuser “Sensor (fuser output) late jam service check.”...
  • Page 56 4062 Previous Error code or Error contents Description/Action Possible repair actions message 201.27 Sensor (fuser output) The media is late reaching the Go to sensor (fuser output) late late jam. sensor (fuser output) within the jam service check. Next specified time. Type 2 fuser “Sensor (fuser output) late jam service check.”...
  • Page 57 4062 Previous Error code or Error contents Description/Action Possible repair actions message 201.51 Main drive motor The main drive motor assembly 1. Check all connections on assembly load error. has failed or caused high the main drive motor Next mechanical load due to paper assembly.
  • Page 58 4062 Previous Error code or Error contents Description/Action Possible repair actions message 201.57 Sensor (fuser output) The media is late reaching the Go to sensor (fuser output) late late jam sensor (fuser output) within the jam service check. Next specified time. Type 1 fuser “Sensor (fuser output) late jam service check.”...
  • Page 59 4062 Previous Error code or Error contents Description/Action Possible repair actions message 201.80 Operator panel door The printer detected that the 1. Remove all media present assembly interlock switch (operator panel door in media path. Next switch open failure interlock) did not cycle prior to 2.
  • Page 60 4062 Previous Error code or Error contents Description/Action Possible repair actions message 202.04 Sensor (fuser output) The sensor (fuser output) Go to sensor (fuser output) bounce rebounded once the trailing service check. Next edge of the media passed. Type 1 fuser “Sensor (fuser output) service check”...
  • Page 61 4062 Previous 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. Next area. 2.
  • Page 62 4062 Previous 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. Next it in the specified time. Type 2 fuser “Sensor (fuser output) lingering jam service check.”...
  • Page 63 4062 Previous 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. Next it in the specified time. Destination is “Sensor (fuser output) standard bin.
  • Page 64 4062 Previous 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. Next it in the specified time. Destination is “Sensor (fuser output) standard bin.
  • Page 65 4062 Previous 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. Next warm up sequence. “Sensor (fuser Type 2 fuser output) static jam service...
  • Page 66 4062 Previous 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. Next it in the specified time. Destination is output “Sensor (fuser output) option.
  • Page 67 4062 Previous 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. Next mechanical load during the 2. Ensure that upper redive warm up sequence.
  • Page 68 4062 Previous 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. Next 2. Check for obstructions in Source = Internal media path.
  • Page 69 4062 Previous 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. Next high mechanical load during 2.
  • Page 70 4062 Previous Error code or Error contents Description/Action Possible repair actions message 230.18 Internal duplex drive The internal duplex drive motor 1. Remove all media present motor assembly does not rotate at the specified in media path. Next underspeed error. speed.
  • Page 71 4062 Previous 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. Next specified time. 2. Check media for proper Source = External installation.
  • Page 72 4062 Previous 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. Next 2. Check media for proper Source = External installation.
  • Page 73 4062 Previous 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. Next warm up sequence. 2. Replace the external duplex assembly if problem Source = External remains.
  • Page 74 4062 Previous 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. Next 2. Check media for proper Source = External installation.
  • Page 75 4062 Previous 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. Next 2. Check media for proper Source = External installation.
  • Page 76 4062 Previous 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. Next 2. Check media for proper Source = External installation.
  • Page 77 4062 Previous 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. Next the specified time. 2.
  • Page 78 4062 Previous 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. Next Source = Media tray 1 due to paper jam or bind.
  • Page 79 4062 Previous 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. Next specified time. Source = Tray 1 “Sensor (input) late jam service check.”...
  • Page 80 4062 Previous 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. Next the specified time. Source = Tray 2 “Sensor (pass through) late jam service check”...
  • Page 81 4062 Previous 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. Next the motor was turned off. 2.
  • Page 82 4062 Previous 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 Next obstructed.
  • Page 83 4062 Previous 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. Next Source = Media tray 2 due to paper jam or bind.
  • Page 84 4062 Previous 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. Next Source = Media tray 2 2.
  • Page 85 4062 Previous 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. Next the specified time. Source = Tray 3 “Sensor (pass through) late jam service check”...
  • Page 86 4062 Previous 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. Next 2. Replace the media out Source = Tray 3 actuator if problem remains.
  • Page 87 4062 Previous Error code or Error contents Description/Action Possible repair actions message 243.50 HCIT tray lift motor The HCIT tray lift motor does 1. Ensure the HCIT media tray underspeed failure not rotate at the specified assembly is properly inserted Next speed.
  • Page 88 4062 Previous Error code or Error contents Description/Action Possible repair actions message 243.66 Pick motor The pick motor does not rotate 1. Remove all media present underspeed failure at the specified speed. in media path. Next 2. Ensure media tray is not Source = Media tray 3 overfilled.
  • Page 89 4062 Previous Error code or Error contents Description/Action Possible repair actions message 243.69 Pick motor control The pick motor does not reach 1. Remove all media present failure. the proper operating speed at in media path. Next the specified time. 2.
  • Page 90 4062 Previous Error code or Error contents Description/Action Possible repair actions message 244.10 Sensor (pass through) The media is late reaching the Go to sensor (pass through) late jam sensor (pass through) within late jam service check. Next the specified time. Source = Tray 4 “Sensor (pass through) late jam service check”...
  • Page 91 4062 Previous Error code or Error contents Description/Action Possible repair actions message 244.36 Sensor (pass through) Media remains on the sensor Go to sensor (pass through) static jam (input) during the warm up static jam service check. Next sequence. Source = Tray 4 “Sensor (pass through) static jam service check”...
  • Page 92 4062 Previous Error code or Error contents Description/Action Possible repair actions message 244.52 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 Next the motor has turned off.
  • Page 93 4062 Previous Error code or Error contents Description/Action Possible repair actions message 244.67 Pick motor overspeed The pick motor does not rotate 1. Remove all media present failure at the specified speed. in media path. Next 2. Ensure media tray is not Source = Media tray 4 overfilled.
  • Page 94 4062 Previous Error code or Error contents Description/Action Possible repair actions message 245.00 Media tray 5 area jam The media is jammed in the 1. Remove all media present media tray 5 area. in media path. Next 2. Check media for proper installation.
  • Page 95 4062 Previous Error code or Error contents Description/Action Possible repair actions message 245.17 Media tray pulled jam A media tray above the source 1. Remove all media present tray was pulled during the in media path. Next Source = Tray 5 printing process.
  • Page 96 4062 Previous Error code or Error contents Description/Action Possible repair actions message 245.49 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 Next obstructed.
  • Page 97 4062 Previous Error code or Error contents Description/Action Possible repair actions message 245.65 Pick motor load error The pick motor has failed or 1. Remove all media present caused high mechanical load in media path. Next Source = Media tray 5 due to paper jam or bind.
  • Page 98 4062 Previous Error code or Error contents Description/Action Possible repair actions message 245.68 Pick motor stop error Pick motor stop error detected 1. Remove all media present by options tray x in media path. Next Source = Media tray 5 2.
  • Page 99 4062 Previous Error code or Error contents Description/Action Possible repair actions message 250.08 Sensor (input) late The media is late reaching the Go to sensor (input) late jam sensor (input) within the service check. Next specified time. Source = MPF “Sensor (input) late jam service check.”...
  • Page 100 4062 Previous Error code or Error contents Description/Action Possible repair actions message 260.02 Envelope feeder Mechanical feed error or timing 1. Remove the envelope assembly error error. feeder. Next 2. Remove all media present in media path. 3. Check media for proper installation.
  • Page 101 4062 Previous Error code or Error contents Description/Action Possible repair actions message 260.10 Sensor (input) late The media is late reaching the Go to sensor (input) late jam sensor (input) within the service check. Next specified time. Source = Envelope “Sensor (input) late jam feeder service check.”...
  • Page 102 4062 Previous Error code or Error contents Description/Action Possible repair actions message 271.05 Sensor (output pass The media reached the sensor “Sensor (output pass through) lingering jam (output pass through) but did through) lingering jam Next x = bin not clear it in the specified time. service check”...
  • Page 103 4062 Previous Error code or Error contents Description/Action Possible repair actions message 27x.50 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 Next x = bin failure...
  • Page 104 4062 Previous Error code or Error contents Description/Action Possible repair actions message 27x.54 Sensor (output pass The media reached the sensor “Sensor (output pass through) lingering jam (output pass through) but did through) lingering jam Next x = bin not clear it in the specified time. service check”...
  • Page 105 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.31 Transport motor The output option transport 1. Check all connections on the encoder not detected motor encoder is not detected output option controller card. Next x = bin upon startup.
  • Page 106 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.36 Stapler drive motor The stapler assembly has 1. Check all the connections on jammed jammed while stapling or the the controller card and the Next x = bin stapler drive motor has failed.
  • Page 107 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.39 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 Next x = bin detect a ready staple in the stapler assembly.
  • Page 108 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.41 Left tamper does not The sensor (left tamper HP) 1. Check all the connections on move to home does not detect that the tamper the output option controller Next x = bin position failure.
  • Page 109 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.43 Right tamper does not The sensor (right tamper HP) 1. Check all the connections on move to home does not detect that the tamper the output option controller Next x = bin position failure.
  • Page 110 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.48 Deflector gate The sensor (deflector gate HP) 1. Check all the connections on transition to output does not detect transition of the the output option controller Next x = bin option not detected deflector gate to the output...
  • Page 111 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.51 Right tamper home The right tamper home position 1. Check all the connections on position jam is not detected by the sensor the output option controller Next x = bin (right tamper HP) card.
  • Page 112 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.58 Sensor (stapler pass The media is late reaching the “Sensor (output pass through) late jam sensor (stapler pass through) through) late jam service Next x = bin within the specified time.
  • Page 113 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.64 Bin clamp motor A software failure has occurred 1. Turn the machine off/on. control timer error with the output option. Next x = bin 2. Replace the output option if during tray holder number problem remains.
  • Page 114 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.69 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 Next x = bin detect a ready staple in the stapler assembly.
  • Page 115 4062 Previous Error code or Error contents Description/Action Possible repair actions message 28x.71 Deflector gate The sensor (deflector gate HP) 1. Check all the connections on transition to standard does not detect transition of the the output option controller Next x = bin bin not detected deflector gate to the standard...
  • Page 116 4062 Previous Error code or Error contents Description/Action Possible repair actions message 903.xx Paperport link driver Code detected unusual event 1. POR the machine and print error or timing. a simple test page to Next determine if the problem is system software related, or if the customer is sending a corrupted print job.
  • Page 117 4062 Previous Error code or Error contents Description/Action Possible repair actions message 910.00 Pick arm motor stalled The pick arm motor has stalled 1. Check all the connections on failure or become obstructed. the pick arm assembly. Next 2. Check all the connections on the system card assembly.
  • Page 118 4062 Previous Error code or Error contents Description/Action Possible repair actions message 915.00 Redrive motor The redrive motor encoder 1. Check all the connections on encoder not detected detection is lost during normal the redrive motor assembly. Next failure operation. 2.
  • Page 119 4062 Previous Error code or Error contents Description/Action Possible repair actions message 917.00 Problem with transfer Problem with transfer -- 1. Check HVPS. -- transfer servo start transfer servo start error 2. Check system board. Next error 3. Check HVPS/ input sensor / toner sensor cable.
  • Page 120 4062 Previous Error code or Error contents Description/Action Possible repair actions message 920.03 Fuser warm-up failure The fuser hot roll is too cool 1. Turn the machine off/on while checking for slope and ensure the fuser unit Next Fuser type = 1 change in standby.
  • Page 121 4062 Previous Error code or Error contents Description/Action Possible repair actions message 920.07 Fuser warm-up failure The fuser hot roll temperature 1. Turn the machine off/on is not maintained properly and ensure the fuser unit Next Fuser type = 1 while the media in the fuser assembly is properly nip.
  • Page 122 4062 Previous Error code or Error contents Description/Action Possible repair actions message 920.28 Fuser warm-up failure The fuser hot roll is too cool 1. Turn the machine off/on while checking for slope and ensure the fuser unit Next Fuser type = 2 change in standby.
  • Page 123 4062 Previous Error code or Error contents Description/Action Possible repair actions message 920.32 Fuser warm-up failure The fuser hot roll temperature 1. Turn the machine off/on is not maintained properly and ensure the fuser unit Next Fuser type = 2 while the media in the fuser assembly is properly nip.
  • Page 124 4062 Previous Error code or Error contents Description/Action Possible repair actions message 920.57 Fuser warm-up failure The fuser hot roll temperature Replace the fuser unit is not maintained properly assembly if problem remains. Next Fuser type = 1 while the media in the fuser Go to “Fuser unit assembly nip.
  • Page 125 4062 Previous Error code or Error contents Description/Action Possible repair actions message 922.02 Fuser warm-up failure The fuser hot roll does not 1. Turn the machine off/on reach the “beginning lamp and ensure the fuser unit Next Fuser type = 1 detection”...
  • Page 126 4062 Previous 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 Next Fuser type = 1 detection”...
  • Page 127 4062 Previous 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 Next Fuser type = 1 after increasing interpage gap.
  • Page 128 4062 Previous 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 Next Fuser type = 2 parameter but not in the assembly is properly specified time.
  • Page 129 4062 Previous 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 Next Fuser type = 2 new enhanced control.
  • Page 130 4062 Previous Error code or Error contents Description/Action Possible repair actions message 922.53 Fuser warm-up failure The fuser hot roll does reach Replace the fuser unit the “final lamp detection” assembly if problem remains. Next Fuser type = 1 parameter but not in the Go to “Fuser unit assembly specified time.
  • Page 131 4062 Previous 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 Next temperature. assembly is properly Fuser type = 1 installed.
  • Page 132 4062 Previous 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. Next temperature. Go to “Fuser unit assembly Fuser type = 2 removal”...
  • Page 133 4062 Previous 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 Next fuser lamp has an excessive assembly is properly...
  • Page 134 4062 Previous 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 Next fuser lamp has an excessive assembly is properly...
  • Page 135 4062 Previous 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 Next fuser lamp has an excessive assembly is properly...
  • Page 136 4062 Previous 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. Next 2. Check the connections on the main cooling fan.
  • Page 137 Replace the printhead intermittent H sync installed. Hsync signal is assembly. Go to “Printhead intermittent or noisy. Printhead assembly removal (T650)” on ID resistor circuit is not to spec. page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60.
  • Page 138 Printhead lost laser H The hsync signal is missing or Replace the printhead syncs. not at the correct voltage. assembly. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. 933.00 Polygon mirror motor...
  • Page 139 4062 Previous Error code or Error contents Description/Action Possible repair actions message 936.10 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. Next 2. Check all connections on No halls detected at the main drive motor motor start.
  • Page 140 4062 Previous Error code or Error contents Description/Action Possible repair actions message 936.30 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. Next 2. Check all connections on No lock detected at the main drive motor motor start for motor...
  • Page 141 4062 Previous Error code or Error contents Description/Action Possible repair actions message 936.90 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. Next 2. Check all connections on Stall detected during the main drive motor speed control.
  • Page 142 4062 Previous Error code or Error contents Description/Action Possible repair actions message 937.50 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. Next 2. Check all connections on Over speed detected the main drive motor during position...
  • Page 143 4062 Previous Error code or Error contents Description/Action Possible repair actions message 937.71 Main drive motor The main drive motor assembly Warning: Ensure that the assembly failure may be faulty or has failed. metal frame of the internal Next duplex assembly is properly Loss of lock detected The internal duplex assembly grounded to the metal frame of...
  • Page 144 4-75. 940.00 LVPS failure LVPS zero cross test failure Replace the LVPS card assembly. Go to “LVPS card assembly removal (T650)” on page 4-28 “LVPS card assembly removal (T652, T654, T656)” on page 4-30. 947.00 System card failure RAM test incomplete.
  • Page 145 The NVRAM chip has failed on Replace the operator panel the operator panel door door assembly. assembly. Go to “Operator panel door assembly removal (T650, T652, T654)” on page 4-43. If problem remains, replace the fuser unit assembly. Go to “Fuser unit assembly removal”...
  • Page 146 4062 Previous Error code or Error contents Description/Action Possible repair actions message 956.xx System card The processor has failed on Replace the system card processor failure the system card assembly. assembly. Next Go to “System card assembly removal” on page 4-75.
  • Page 147 4062 Previous Error code or Error contents Description/Action Possible repair actions message 976.xx Network Error The system detected an Replace the system card unrecoverable software error in assembly. Next network port Go to “System card assembly removal” on page 4-75. Go Back 978.xx Network Error...
  • Page 148 4062 Previous 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 Next 2. Remove and reinstall the failure.
  • Page 149 4062 Previous Error code or Error contents Description/Action Possible repair actions message 985.01 Service engine RFID Generic hardware error 1. Check the RFID firmware communications card, RFID interface card, Next RFID cable, and RFID option for correct installation. Go to Go Back “Installing / Removing the RFID UHF option”...
  • Page 150 4062 Previous Error code or Error contents Description/Action Possible repair actions message 985.04 Service engine RFID Radio communications are out 1. Check the RFID firmware communications of sync card, RFID interface card, Next RFID cable, and RFID option for correct installation.
  • Page 151 4062 Previous Error code or Error contents Description/Action Possible repair actions message 985.07 Service engine RFID Antenna is disconnected 1. Check the RFID firmware communications card, RFID interface card, Next RFID cable, and RFID option for correct installation. Go to Go Back “Installing / Removing the RFID UHF option”...
  • Page 152 4062 Previous Error code or Error contents Description/Action Possible repair actions message 990.11 Paperport failure Paperport parity error Replace the system card assembly. Next Go to “System card assembly removal” on page 4-75. Go Back 990.12 Paperport failure Paper port other paper port Replace the system card error assembly.
  • Page 153 4062 Previous Error code or Error contents Description/Action Possible repair actions message 990.54 HCIT tray lift motor The HCIT tray lift motor is not 1. Check for obstruction in the lost encoder failure reporting pulses back to the HCIT tray lift area. Next engine.

  • Page 154: Sensor (Input) Service Check

    4062 Previous Service checks Sensor (input) service check Next Step Check Check the sensor (input) for damage. Go to step 2. Replace the Go Back sensor (input). Is the above component free from damage? Go to “Sensor (input) removal” on page 4-70.

  • Page 155: Sensor (Narrow Media) Service Check

    4062 Sensor (narrow media) service check Previous Step Check Check the sensor (narrow media) for damage. Go to step 2. Replace the fuser Next unit assembly. Is the above component free from damage? Go to “Fuser unit assembly Go Back removal”...

  • Page 156: Sensor (Duplex Input) Service Check (External Duplex Only)

    4062 Previous Step Check Check the above sensor for proper connection. Replace the Replace the duplex input connection. Is the above sensor connected properly? sensor assembly Next (internal duplex only). Go to “Duplex input sensor Go Back assembly removal (T652, T654, T656)”...

  • Page 157: Sensor (Pass Through) Service Check

    4062 Sensor (pass through) service check Previous Step Check 1. Enter the diagnostic mode The sensor is Go to step 2. Next working properly 2. Select Input tray tests 3. Select Sensor test Go Back 4. Select the appropriate tray number 5.
  • Page 158 4062 Previous Step Check Check the media size setup and tray guides for all media Go to step 2. Replace the trays. media, or change the media size Does the media size, in use, match the size set for all media Next setup.
  • Page 159 4062 Previous Step Check Perform a print test and check the duplex drive motor Go to step 17. Replace the assembly for proper operation. duplex drive motor assembly. Does the above component operate properly? Next Go to “Duplex drive motor assembly removal (T652, Go Back...

  • Page 160: Sensor (Input) Lingering Jam Service Check

    4062 Previous Step Check Perform a print test and check the pick arm assembly. Go to step 21. Replace the pick arm assembly. Go Is the media properly picked and advanced out of the media “Pick arm tray? Next assembly removal”...

  • Page 161: Sensor (Input) Early Jam Service Check

    4062 Previous Step Check Check the sensor (fuser output) for proper operation. Go to step 8. Go to step 7. 1. Enter the diagnostic mode Next 2. Select Base sensor test 3. Observe the line item “exit” Go Back Caution: The area around the actuator is very hot. Allow the fuser area to cool before proceeding.
  • Page 162 4062 Previous Step Check Perform a MPF print test and check the MPF pick solenoid Go to step 4. Replace the MPF for proper operation. pick solenoid. Does the above component operate properly? Go to “MPF pick Next solenoid assembly removal”...

  • Page 163: Sensor (Input) Static Jam Service Check

    4062 Sensor (input) static jam service check Previous Use this procedure for the following jams: • 200.13 Next Step Check Go Back 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 164 4062 Previous Step Check Check the sensor (fuser output) for proper operation. Go to step 7. Go to step 6. 1. Enter the diagnostic mode Next 2. Select Base sensor tests 3. Observe the line item “output” Does the display on the operator panel, change every time Go Back the sensing area of the above sensor is interrupted or blocked.

  • Page 165: Sensor (Fuser Output) Lingering Jam Service Check

    4062 Sensor (fuser output) lingering jam service check. Previous Use this procedure for the following jams: • 202.01 • 202.02 • 202.07 • 202.10 • 202.11 • 202.12 • 202.26 • 202.27 • 202.32 • 202.34 Next • 202.35 • 202.36 •...

  • Page 166: Sensor (Fuser Output) Static Jam Service Check

    4062 Previous Step Check Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support. Next Sensor (fuser output) static jam service check Go Back Use this procedure for the following jams: • 202.06 •...

  • Page 167: Sensor (Narrow Media) Late Jam Service Check

    4062 Sensor (narrow media) late jam service check. Previous Use this procedure for the following jams: • 201.04 • 201.06 • 201.29 • 201.31 • 201.54 • 201.56 • 201.79 • 201.81 Next Go Back Step Check Check the media size setup and tray guides for all media Go to step 2.

  • Page 168: Sensor (Narrow Media) Static Jam Service Check

    4062 Previous Step Check Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support. Next Sensor (narrow media) static jam service check Go Back Use this procedure for the following jams: • 202.03 •...

  • Page 169: Sensor (Duplex Input) Late Jam Service Check

    4062 Sensor (duplex input) late jam service check. Previous Use this procedure for the following jams: • 230.02 • 231.00 Next Step Check Go Back Check the door assembly, rear. Go to step 2. Open then properly close the Is the above component properly closed? door assembly, rear.

  • Page 170: Sensor (Duplex Input) Lingering Jam Service Check

    4062 Previous Step Check Perform a print test and check the duplex drive motor Go to step 14. Replace the assembly for proper operation. duplex drive motor assembly. Does the above component operate properly? Next Go to “Duplex drive motor assembly removal (T652, Go Back...
  • Page 171 4062 Previous Step Check Check the sensor (duplex input) for proper operation. Go to step 6. Go to step 5. 1. Enter the diagnostic mode Next 2. Select Duplex tests 3. Select sensor test 4. Observe the line item “input” Go Back Does the display on the operator panel, change every time the sensing area of the above sensor is interrupted or...

  • Page 172: Sensor (Duplex Input) Static Jam Service Check

    4062 Sensor (duplex input) static jam service check. Previous Use this procedure for the following jams: • 230.13 • 238.01 • 238.03 • 238.05 • 238.07 Next Step Check Go Back Check media origination. Go to step 2 Go to step 5 Did the media originate from the internal duplex? Check the media path for partially fed or jammed media.
  • Page 173 4062 Sensor (pass through) late jam service check Previous 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 Next • 243.04 • 243.04 •...
  • Page 174 4062 Previous 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 Next appropriate media tray? Go to “Operator...

  • Page 175: Sensor (Pass Through) Static Jam Service Check

    4062 Previous Step Check Check the above sensor for proper connection. Replace the Replace the appropriate connection. Is the above sensor connected properly? Sensor (pass Next through). Go to “250-sheet controller card assembly Go Back removal” on page 4-106. 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

    4062 Sensor (stapler pass through) late jam service check Previous Step Check Check the output option for proper installation. Go to step 2. Remove then Next 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 4062 Previous Step Check Check the above sensor for proper connection. Replace the Replace the stapler unit connection. Is the above sensor connected properly? assembly. Next Go to “SFP stapler assembly stapler unit assembly Go Back removal” on page 4-183. Perform a print test using the output option.

  • Page 178: Sensor (Output Pass Through) Lingering Jam Service Check

    4062 Previous Step Check Check for obstructions in the media path between the base Go to step 3. Remove machine and the output option. obstructions. Is the media path free from obstructions? Next Check the sensor (output pass through) for proper Go to step 5.
  • Page 179 4062 Previous Step Check Check the sensor (output pass through) for proper Go to step 5. Go to step 4. operation. 1. Enter the diagnostic mode Next 2. Select Output bin tests 3. Select Sensor test Go Back 4. Select Output bin x 5.

  • Page 180: Sensor (Mailbox Empty) Late Jam Service Check

    4062 Previous Step Check Check the above sensor for proper connection. Replace the Replace the sensor (output connection. Is the above sensor connected properly? pass through). Next Go to “High capacity stacker sensor (pass through) Go Back removal” on page 4-145.

  • Page 181: Sensor (Mailbox Empty) Lingering Jam Service Check

    4062 Sensor (mailbox empty) lingering jam service check Previous Step Check Check the output option for proper installation. Go to step 2. Remove then Next reinstall the output Is the above component properly installed? option Check for obstructions in the media path between the Go to step 3.

  • Page 182: Sensor (Toner Empty) Service Check

    4062 Previous Step Check Check the above sensor for proper connection. Replace the Replace the sensor (mailbox connection. Is the above sensor connected properly? empty). Next Go to “5-bin mailbox sensor (media bin empty) removal” Go Back on page 4-91. Perform a print test using the output option.

  • Page 183: System Software Error (900.Xx) Service Check

    Note: Before troubleshooting, determine the operating system used when the error occured. If possible determine whether a PostScript or PCL file was sent to the device when the error occured. Ask the customer which Lexmark Solutions applications are installed on the device. Step Action and questions POR the device.
  • Page 184 Reinstall the memory, and send a print job to the Go to step 15. Go to step 16. device. Does the 900.xx error reoccur? Install a Lexmark recommended memory option. Send Go to step 31. Problem a print job to the device. resolved.
  • Page 185 4062 Previous Step Action and questions Upgrade the firmware. Contact your next level of Go to step 19. Problem support for the correct firmware level to use. resolved. Restart the printer to operating mode. Send the printer a print job. Next Does the 900.xx error reoccur? Replace the modem.

  • Page 186: Image Quality Trouble

    4062 Previous 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. Next Image quality symptoms Go Back • Faint print (low contrast)— “Faint print (Low contrast)” on page 2-151.

  • Page 187: Image Quality

    4062 Image Quality Previous Faint print (Low contrast) Leading edge Next Go Back 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.
  • Page 188 Replace the printhead connections. Is the above component properly connected? assembly. Next Go to “Printhead assembly Go Back removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Perform a print test. Contact next Problem solved.

  • Page 189: Blank Print (No Print)

    Replace the left and or right Are the above components free from damage? transfer roll brackets. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Check the transfer roll assembly for contamination and Go to step 6.
  • Page 190 Replace the Replace the printhead connections. Is the above component properly connected? assembly. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Check the system card assembly for proper connection. Replace the...

  • Page 191: Solid Black

    4062 Solid black Previous Next Go Back 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 192: Vertical Lines And Bands (Process Direction)

    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 (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Perform a print test. Contact next Problem solved.

  • Page 193: Horizontal White Stripes Or Bands (Side To Side Direction)

    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 (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Perform a print test. Contact next Problem solved.

  • Page 194: Vertical Stripes (Process Direction)

    4062 Vertical stripes (process direction) Previous Leading edge Next Go Back 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 195: Horizontal Stripes (Side To Side Direction)

    4062 Previous Step Check Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support. Next Horizontal stripes (side to side direction) Go Back Leading edge Trailing edge Step Check Check the media condition. Go to step 2.
  • Page 196 4062 Previous Step Check Check the heat roll and pressure roll. Replace the Go to step 7. fuser unit Remove the fuser unit assembly. assembly. Next CAUTION: : Allow Go to “Fuser the fuser unit unit assembly assembly to cool removal”...

  • Page 197: Partial Lack

    Go to step 6. Reinstall and adjust the Is the above component properly installed? printhead assembly. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Perform a print test. Contact next Problem solved.

  • Page 198: Spots

    4062 Spots Previous Leading edge Next Go Back 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.

  • Page 199: After Image

    Reinstall and adjust the Is the above component properly installed? printhead Next assembly. Go to “Printhead Go Back assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. Perform a print test. Contact next Problem solved.
  • Page 200 4062 Previous Step Check Check the heat roll and pressure roll. Replace the Go to step 4. fuser unit Remove the fuser unit assembly. assembly. Next CAUTION: : Allow Go to “Fuser the fuser unit unit assembly assembly to cool removal”...

  • Page 201: Background (Fog)

    Check the printhead installation. Go to step 7. Reinstall and adjust the Is the above component properly installed? printhead assembly. Go to “Printhead assembly removal (T650)” on page 4-59 “Printhead assembly removal (T652, T654, T656)” on page 4-60. 2-165 Diagnostic information...

  • Page 202: Skew

    4062 Previous Step Check Perform a print test. Contact next Problem solved. highest level of Does the problem remain? tech support. Next Skew Go Back Leading edge Trailing edge The printed image is not paralleled with both sides of the media. Step Check Check printer installation placement.

  • Page 203: Media Damage

    4062 Previous Step Check Check the aligner assembly for proper adjustment. Go to step 6. Replace the aligner Go to “Alignment assembly adjustment” on assembly. Next page 4-4. Go to “Output Does the problem remain? cover assembly Go Back removal” on page 4-53.
  • Page 204 4062 Previous Step Check Check the transfer roll assembly for contamination and Go to step 5. Replace the wear. transfer roll assembly. Next Is the above component free of excess wear and contamination? Go to “Transfer roll assembly removal” on Go Back page 4-80.

  • Page 205: No Fuse

    4062 No fuse Previous Leading edge Next Go Back Trailing edge Step Check Check the media type and printer media settings. Go to step 2 Adjust to the correct settings. Does the printer media settings match the media type? Check the fuser unit assembly installation. Go to step 3.

  • Page 206: Network Service Check

    Have the network administrator verify that the device is using the correct SSID, and wireless security protocols. For more network troubleshooting information, consult the Lexmark Network Setup Guide. Step...
  • Page 207 4062 Previous Step Questions / actions Using the subnet address supplied by the Problem resolved. Go to step 12. network administrator, assign a unique IP address to the printer. Note: The printer IP address should match Next the IP address on the printer driver. Did this fix the problem? Is the device physically connected (ethernet Go to step 13.
  • Page 208 4062 Previous Next Go Back 2-172 Service Manual...

  • Page 209: Diagnostic Aids

    3. Diagnostic aids Previous This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the problem. Next Understanding the printer control panel (models T650, T652, and T654) Go Back Item Description Display Shows messages and pictures that communicate the status of the printer.

  • Page 210: Accessing Service Menus (Models T650, T652, And T654)

    Insert a flash drive into the front of the printer to print saved files. Note: Only the front USB port supports flash drives. Go Back Accessing service menus (models T650, T652, and T654) There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Mode 1.

  • Page 211: Diagnostics Mode (Models T650, T652, And T654)

    4062-XXX Previous Diagnostics mode (models T650, T652, and T654) Entering Diagnostics mode (models T650, T652, and T654) 1. Turn the printer off. Next 1. Press and hold 2. Turn the printer on. Go Back 3. Release the buttons after 10 seconds.
  • Page 212 4062-XXX DUPLEX TESTS (if installed) Previous Quick Test “Quick Test (duplex)” on page 3-12 Top Margin “Top Margin (duplex)” on page 3-13 Sensor Test “Sensor Test (duplex)” on page 3-13 Motor Test “Motor Test (duplex)” on page 3-14 Next Duplex Feed 1 “Duplex Feed 1”...

  • Page 213: Exiting Diagnostics Mode (Models T650, T652, And T654)

    Clear Log “Clear Log” on page 3-24 EXIT DIAGNOSTICS Exiting Diagnostics mode (models T650, T652, and T654) Select Exit Diagnostics to exit the Diagnostics menu. Resetting the Printer displays, the printer performs a POR, and returns to Ready mode. REGISTRATION Print registration makes sure the printing is printed properly aligned on the page.

  • Page 214: Quick Test

    4062-XXX The print registration range is: Previous Variable Description Value Direction of change Top margin -25 to +25 Each increment causes A positive change moves the image approximately 4 pels shift (at 600 down the page and increases the dpi). top margin.

  • Page 215: Print Tests

    4062-XXX PRINT TESTS Previous 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 Next selected input source.

  • Page 216: Hardware Tests

    4062-XXX NVRAM. The CONFIG MENU print quality test pages are identical to the DIAGNOSTIC print quality test pages Previous with the exception of the first page. The first print quality test page from the CONFIG MENU does not include EP or Printer setup. HARDWARE TESTS Next Select the following Hardware Tests from this menu:...

  • Page 217: Usb Hs Test Mode

    4062-XXX USB HS Test Mode Previous 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 Next Port Test Appears on the display Go Back...

  • Page 218: Rfid Option Test

    4062-XXX RFID Option Test Previous This test confirms that the RFID firmware and hardware are working properly. In the event that the test fails, it is recommended that the test be repeated to confirm that the problem is not intermittent or caused by a single failed piece of RFID media.
  • Page 219 4062-XXX 2. Reload RFID media in Tray 2 with the RFID media that was just printed in step 1, and then press continue. Previous The test page will be printed. Note: The sheet should be placed face down with the arrow pointing toward the front of the printer. If the page looks like this: If the page looks like this: If the page looks like this:...

  • Page 220: Duplex Tests

    4062-XXX 3. Load plain media in Tray 2, and then press Continue. The test page will be printed. Previous If the page looks like this: If the page looks like this: Next T65x RFID Option Test T65x RFID Option Test Step 3.

  • Page 221: Top Margin (Duplex)

    4062-XXX duplexed pages (Continuous) until Stop is pressed. For information about changing the margin, see Previous “Top Margin (duplex)” on page 3-13. Note: Before you set the duplex top margin, be sure to set the registration. See “REGISTRATION” on page 3-5.

  • Page 222: Motor Test (Duplex)

    4062-XXX • Duplex input sensor Previous • Duplex exit sensor 3. Press Back or Stop to exit the test. Motor Test (duplex) Next This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values are acceptable.

  • Page 223: Feed Tests (Input Tray)

    4062-XXX Feed Tests (input tray) Previous 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 224: Feed To All Bins

    4062-XXX Use these tests to verify that media can be fed to a specific output bin. Media is fed from the default input Previous source to the selected output bin. No information is printed on the media fed to the output bin because the printhead is not engaged during this test.

  • Page 225: Sensor Test (High Capacity Output Stacker)

    4062-XXX To run the Sensor Test for the standard bin: Previous 1. Select Sensor Test from OUTPUT BIN TESTS. 2. Select Standard Bin from Sensor Tests. 3. Standard Bin Testing displays briefly, and then Bin Empty empty displays. Next 4. Select NearFull or Full sensor to test. The following screen is displayed: Standard Bin x Go Back...

  • Page 226: Sensor Tests (5-Bin Mailbox)

    4062-XXX Sensor Tests (5-bin mailbox) Previous 1. Select Sensor Tests from OUTPUT BIN TESTS. 2. Select Output Bin x (x=number of the output option to be tested). The following screen is displayed: Next Output Bin x P1=OP P2=OP L=NL • passThru—5-bin mailbox pass thru sensor shows Open or Closed Go Back •...

  • Page 227: Base Sensor Test

    4062-XXX To run the Finisher Sensor Test: Previous 1. Select Sensor Test from FINISHER TESTS. 2. Select one of the four tests to perform:. Each of the tests displays the individual sensors that can be manually actuated, and the display shows Open or Closed. •...

  • Page 228: Perm Page Count (Permanent Page Count)

    4062-XXX The page count can only be viewed and cannot be changed. Previous To view the page count: 1. Select Page Count from PRINTER SETUP. 2. Press Back to return to PRINTER SETUP. Next Perm Page Count (permanent page count) Go Back The permanent page count can only be viewed and cannot be changed.

  • Page 229: Edge To Edge

    4062-XXX • To change a digit or character, press to increase or to decrease the value. Previous • When the last digit is changed, press to validate the Configuration ID 1. If Invalid ID appears, the entry is discarded, and the previous Configuration ID 1 is displayed on the screen.

  • Page 230: Print Contrast

    4062-XXX Print Contrast Previous 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. Next Charge Roll The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium. Go Back Gap Adjust The setting adjusts the minimum gap between sheets.

  • Page 231: Reports

    4062-XXX REPORTS Previous Prints a Menu Settings Page. To print the Menu Settings Page: Next 1. Select Menu Settings Page from REPORTS. 2. Press Back to return to DIAGNOSTICS. Go Back EVENT LOG Display Log The event log provides a history of printer errors. It contains the 12 most recent errors that have occurred on the printer.

  • Page 232: Clear Log

    Additional debug information in some cases Previous Next Go Back The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Select Print Log from EVENT LOG. Press Back to return to EVENT LOG.

  • Page 233: Configuration Menu (Config Menu) (Models T650, T652, And T654)

    4062-XXX Previous Configuration menu (CONFIG MENU) (models T650, T652, and T654) Entering Configuration Menu (models T650, T652, and T654) 1. Turn off the printer. Next 2. Press and hold 3. Turn on the printer. Go Back 4. Release the buttons after ten seconds.

  • Page 234: Maintenance Page Counter Reset (Reset Cnt)

    4062-XXX To view the maintenance page count: Previous 1. Select Maint Cnt Value from CONFIG MENU. 2. Press to view the value. Press Back to return to the main Configuration menu. Next Maintenance page counter reset (Reset Cnt) Go Back After scheduled maintenance, the servicer needs to reset the page counter.

  • Page 235: Size Sensing

    4062-XXX To print the Event Log, select Reports from CONFIG MENU, and then Event Log. The message Printing Previous EVENT LOG is displayed. The event log provides a history of printer errors. The event log can only be printed in CONFIG MENU. SIZE SENSING Next This setting controls whether the printer automatically registers the size of paper installed in an input source...

  • Page 236: Factory Defaults

    Settings in the NETWORK/PORTS MENU group. Go Back LES Applications This disables all installed Lexmark Embedded Solution applications. Settings are Disable and Enable. The default is Enable. Energy Conserve This menu controls what values appear on the Power Saver menu. If Off is selected in Energy Conserve menu, then Disabled appears in the Power Saver menu and Power Saver can be turned off.

  • Page 237: Best Speed

    Settings are For short jobs and For long jobs. Make a setting change, and then press . Submitting selection appears on the display. Exit Config Menu (models T650, T652, and T654) Next Press to exit the CONFIG MENU. The message Resetting the Printer displays, and the printer performs a POR and restarts in normal mode.

  • Page 238: Accessing Service Menus (Model T656)

    4062-XXX Item Description Previous Indicator light Indicates the printer status: • Off—The power is off. • Blinking green—The printer is warming up, processing data, or printing. • Solid green—The printer is on, but idle. • Blinking red—Operator intervention is needed. Next Stop Stops all printer activity...

  • Page 239: Available Tests

    4062-XXX Previous Diagnostics Menu (model T656) Entering Diagnostics Menu (model T656) 1. Turn off the printer. Next 2. Press and hold 3 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Go Back 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 240 4062-XXX Diagnostics Menu tests (Continued) Previous Tray 1 Tray 2 (if installed) Tray 3 (if installed) Next Tray 4 (if installed) Tray 5 (if installed) Envelope Feeder Go Back MP Feeder Sensor Tests “Sensor Test (input tray)” on page 3-41 Tray 1 Tray 2 (if installed) Tray 3 (if installed)

  • Page 241: Registration (Printer)

    4062-XXX Diagnostics Menu tests (Continued) Previous Warm Up Time “Warm Up Time” on page 3-46 Transfer “Transfer” on page 3-46 Print Contrast “Print Contrast” on page 3-46 Next Charge Roll “Charge Roll” on page 3-46 Gap Adjust “Gap Adjust” on page 3-47 Auto Dark Adjust “Auto Dark Adjust”...

  • Page 242: Quick Test

    4062-XXX Previous Description Value Direction of change Left Margin -25 to +25 A positive change moves the image right, and a negative change moves the image left. No compression occurs. Right Margin -10 to +10 A positive change moves the image left, and a Next negative change moves the image right.

  • Page 243: Print Tests

    4062-XXX The message Quick Test Printing… appears on the display. Previous Once the Quick Test Page completes printing, the Registration screen displays again. 3. Touch Back to return to the Diagnostics Menu. PRINT TESTS Next Selections on the screen vary since only installed input sources are listed, followed by Printing Quality Test Pages.

  • Page 244: Hardware Tests

    4062-XXX • Contents of the EVENT LOG from DIAGNOSTICS. Previous • Configuration information, including printer serial number, controller code level, engine code level, operator panel code level, font versions, and cartridge information. • Default values for the QUALITY MENU settings used to print the pages. HARDWARE TESTS Next Select the following Hardware Tests from this menu:...

  • Page 245: Dram Test

    4062-XXX DRAM Test Previous 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: Next 1.

  • Page 246: Duplex Tests

    4062-XXX Previous Port Test Appears on the display Single Step USB High Speed Get Device Certification Testing... Descriptor Next Single Step USB High Speed Set Feature Certification Testing... To stop testing before completion, turn the printer off. Go Back DUPLEX TESTS Quick Test (duplex) This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the top margin on the back side of a duplex page.

  • Page 247: Left Margin (Duplex)

    4062-XXX • An increase moves the top margin down and widens the top margin. A decrease moves the top margin Previous upward and narrows the top margin. 4. Touch Submit. 5. Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary. Left Margin (duplex) Next To set the Left Margin (duplex):...

  • Page 248: Duplex Feed 1

    4062-XXX 2. When the motor stops, the results are displayed. Listed below is an example of such results: Previous Duplex Motor Test Test Passed Avg. PWM of High-Speed Test: 1d Avg. PWM of Low-Speed Test: Oe Max. PWM of Low-Speed Test: 00 Min.

  • Page 249: Sensor Test (Input Tray)

    4062-XXX Sensor Test (input tray) Previous This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test: 1. Touch to select the Sensor Test from INPUT TRAY TESTS. 2. Touch to select the input source from the sources displayed on the Sensor Test menu.

  • Page 250: Base Sensor Test

    4062-XXX To run the Sensor Test for the standard bin: Previous 1. Touch to select Sensor Test from OUTPUT BIN TESTS. 2. Touch to select Standard Bin from Sensor Tests. 3. Manually actuate the bin sensor by moving the flag in and out of the sensor, and the display changes. The following screen is displayed: Next Bin Empty: empty or Bin Empty: full.

  • Page 251: Device Tests

    4062-XXX DEVICE TESTS Previous 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 Next block is good, the saved data is written back to the disk.

  • Page 252: Printer Setup

    4062-XXX PRINTER SETUP Previous PRINTER SETUP Defaults Printed Page Count Next Permanent Page Count Serial Number xxxxxxx Go Back 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 253: Configuration Id

    4062-XXX Configuration ID Previous 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 254: Ep Defaults

    4062-XXX The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to Previous display these additional menus. Note: If you make changes, touch Submit to make the change effective. EP Defaults Next This setting is used to restore each printer setting listed in EP SETUP to its factory default value.

  • Page 255: Gap Adjust

    4062-XXX Touch Back to return to Diagnostics Menu. Previous Gap Adjust The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed media and eliminate some output bin stacking problems. However, increasing this value also results in slower Next overall performance, measured in pages per minute.

  • Page 256: Print Log

    Page counts for most errors • Additional debug information in some cases The printed event log can be faxed to Lexmark or your next level of support for verification or diagnosis. To print the event log: Touch to select Print Log from EVENT LOG.

  • Page 257: Configuration Menu (Config Menu) (Model T656)

    4062-XXX Previous Configuration menu (CONFIG MENU) (model T656) Entering Configuration Menu (model T656) 1. Turn off the printer. Next 2. Press and hold 2 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Go Back Available menus Note: Some menus are not available, depending on the configuration of the printer.

  • Page 258: Reset Maintenance Counter

    4062-XXX The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job Previous containing a single page increments the counter by one and a duplex page by two. At 300,000, the customer is reminded that the printer requires scheduled maintenance.

  • Page 259: Print Quality Pages

    4062-XXX Print Quality Pages Previous The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu (CONFIG MENU). When printed from the Diagnostics Menu, additional information is included, and the print cartridge lockout is bypassed. See “Print quality pages (Prt Quality Pgs)”...

  • Page 260: Size Sensing

    4062-XXX 3. Touch Back to return to EVENT LOG. Previous Note: An event log printed from the CONFIG MENU will not contain debug information or secondary codes for 900 service errors. However, the event log printed from DIAGNOSTICS mode does include this information. SIZE SENSING Next This setting controls whether the printer automatically registers the size of paper installed in an input source...
  • Page 261 4062-XXX To change the PPDS Emulation setting: Previous 1. Touch to select PPDS Emulation from the Configuration Menu. 2. The panel displays the setting's name in the header and [setting's current value] below the header row. Touch to change the setting. The selections are Deactivate and Activate. The default is Deactivate.

  • Page 262: Factory Defaults

    Previous This setting enables a user to restore all the printer settings to the original factory settings. Selections are Restore Base, Restore STD NET, or Restore LES. Restore LES enables you to remove all Lexmark Embedded Solutions applications (LES). Next Network does not appear unless you have a network printer.

  • Page 263: Paper Prompts

    4062-XXX Paper Prompts Previous When a tray is out of the indicated paper size, a prompt is sent to the user to load paper in a tray. This setting controls the tray the user is directed to fill. 1. Touch to select Paper Prompts from the Configuration Menu.

  • Page 264: Disk Encryption

    4062-XXX Disk Encryption Previous If a hard disk is installed, Disk Encryption selects whether the data on the disk is encrypted or not. The values are Disable and Enable. This setting determines if the printer encrypts the information that it writes to the hard disk.

  • Page 265: Wipe Disk

    4062-XXX Wipe Disk Previous 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. Next To change this setting: 1. Touch to select Wipe Disk from Configuration Menu.

  • Page 266: Les Applications

    4062-XXX LES Applications Previous This disables all installed Lexmark Embedded Solution applications. The default is Enable. To change this setting: Next 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 267: Usb Speed

    4062-XXX USB speed Previous To change this setting: 1. Touch to select USB speed from the Configuration Menu. 2. Touch to change the value. The values are Auto (default) and Full. Next 3. Touch Submit to save the change. Touch Back to cancel and return to the Configuration Menu. Go Back Exit Configuration Menu (model T656) Touch Exit Config Menu to exit the Configuration Menu.

  • Page 268: Printer Overview

    4062-XXX Previous 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. Next Basic model Go Back The following illustration shows the basic printer model. Feature Paper Capacity Standard exit bin...

  • Page 269: Printer Theory

    4062-XXX Previous Printer theory Model T650 with duplex, paper path, rolls, and sensors Standard bin full actuator Next and sensor (standard bin full) Sensor (input) PC drum Go Back PC cartridge Diverter Sensor (fuser output) Sensor (narrow media) Sensor (duplex input)

  • Page 270: Models T652 And T654 Paper Path Rolls And Sensors

    4062-XXX Models T652 and T654 paper path rolls and sensors Previous Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Next Diverter PC cartridge Go Back Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm...

  • Page 271: Side Guide

    4062-XXX The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear. Previous 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 Next the side guide to the left or right.

  • Page 272: Pick Arm Assembly

    4062-XXX The media size set for the media tray assembly is transmitted to the switch (media size) by moving these Previous guides. The media size is detected by the on/off information of these switches. Pick arm assembly Sensor (media empty) Next Media out actuator Go Back...

  • Page 273: Switch (Media Size)

    4062-XXX Switch (media size) Previous 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) Next 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 274: Supported Paper Sizes, Types, And Weights

    4062-XXX Supported paper sizes, types, and weights Previous 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 Next Paper sizes supported by the printer Go Back 250-or 550-sheet Optional...

  • Page 275: Registration

    4062-XXX Previous 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 Next (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 276: Transfer Roll Assembly

    4062-XXX Transfer Previous Next Go Back 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 277: Polygon Printhead Assembly

    4062-XXX Polygon printhead assembly Previous 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. Next Go Back Polygon printhead 1.
  • Page 278 4062-XXX Conceptual diagram of an image created by scanning Previous Paper Path 600 dots/inch Next Go Back 600 scans/inch 3-70 Service Manual...

  • Page 279: Oscillating Printhead Assembly

    4062-XXX Oscillating printhead assembly Previous The oscillating printhead scans the photo conductor drum surface with a laser beam. It consists of four components: laser diode (LD) card assembly, magnetic motor, mirror, and the start of scan card assembly. Next Oscillating printhead Go Back 1.

  • Page 280: Fuser

    4062-XXX Fuser Previous Fuser unit assembly Next Go Back Fuser components Hot roll Fuser lamp Sensor(Fuser ou Sensor(Narrow m Fuser solen 3-72 Service Manual...

  • Page 281: Pressure Roll

    4062-XXX Heat roll Previous The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media. Pressure roll Next The pressure roll is used to apply pressure to the media surface for fusing.

  • Page 282: Type 2 Fuser Unit Assembly

    4062-XXX Type 2 fuser unit assembly Previous In the type 2 fuser unit assembly, the detacs, which are used to prevent the media from sticking to the hot roll, do make full contact with the hot roller. The type 2 fuser unit assembly has a life of 150K. Hot roll Fuser lamp Next...

  • Page 283: Drive

    4062-XXX Drive Previous Main drive motor assembly The main drive motor is a DC motor that drives the print cartridge, aligner, MFP and fuser. Next Redrive motor assembly The redrive motor assembly is a DC motor that drives the redrive assembly that transports the media into the Go Back standard bin or output option.

  • Page 284: Electrical Components And Controller

    4062-XXX Electrical components and controller Previous Main cooling fan LVPS card assembly Next Duplex System card cooling fan Go Back assembly Print cartridge cooling fan HVPS card assembly Switch (printer front door interlock) The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt power supply (HVPS) card assembly, printer system card assembly and to the main drive motor assembly, while the printer front door assembly is open.

  • Page 285: System Card Assembly

    4062-XXX System card assembly Previous 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 Next Control Go Back Printhead control Rotation of printhead motor...

  • Page 286: Fuser Warm-Up

    4062-XXX Fuser warm-up Previous 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 287: Charge

    4062-XXX Charge Previous 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.

  • Page 288: Development

    4062-XXX This discharge/no discharge process creates an invisible, electrostatic image on the surface of the drum. This Previous image is called a latent image. Modulated Laser Beam Next Printhead DRUM Go Back Drum Surface Drum Surface Image Voltage Laser Beam Laser Beam Discharge Level...

  • Page 289: Transfer

    4062-XXX Roll, toner transfers from the Magnet Roll to that point on the drum. There is now a visible toner image on the Previous drum surface. The image is called a developed image. HVPS Developer Metering Roll Blade Next Toner DRUM -VDC Go Back...

  • Page 290: Cleaning

    4062-XXX is now stuck to the photoconductor (drum) due to the relative electrical differences between the negative Previous electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper. Next Go Back HVPS -VDC DRUM -VDC...

  • Page 291: Auto Density Sensing

    4062-XXX Auto density sensing Previous Next Go Back Sensor shield assembly Sensor (toner density) The image density sensor assembly uses a reflection type sensor that detects a pre-placed toner patch and image on the photoconductor (drum) and outputs pulses when the central line of the patch image aligns with the central line of the detector.

  • Page 292: High Capacity Input Tray (Hcit) Tray Assembly

    4062-XXX High Capacity Input Tray (HCIT) tray assembly Previous Rear media tray guide Media end guide Next Go Back Pick arm assembly Media size actuator Sensor (media empty) Sensor (media low) Sensor (pass through) Sensor (tray raised HP) HCF drawer assembly Tray lift drive motor 3-84...

  • Page 293: Sheet/550-Sheet Tray Assembly

    4062-XXX 250-sheet/550-sheet tray assembly Previous Lockable back restraint Rear media tray guide Media end guide Next Go Back 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 294: Media Level Sensing

    4062-XXX Media level sensing Previous 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. Next 250-sheet tray Sensor A...

  • Page 295: Switch (Media Size)

    4062-XXX The pick arm assembly (autocompensator) is a paper pick device that generates its own normal force. This Previous force generation is inherent in the fundamental design of the pick arm. If light media is used, it picks very gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore no special trays are needed for card stock or labels.
  • Page 296 4062-XXX Previous Pick arm assembly Next Go Back Sensor (media empty) Sensor (media low) Sensor (pass through) 550-sheet drawer assembly 3-88 Service Manual...

  • Page 297: Media Transport Path

    Previous 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. Model T650 paper path, rolls, and sensors Next Standard bin full actuator and sensor (standard bin full)

  • Page 298: Models T652 And T654 Paper Path, Rolls, And Sensors

    4062-XXX Models T652 and T654 paper path, rolls, and sensors Previous Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Next Diverter PC cartridge Go Back Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm...

  • Page 299: Wear Strips

    4062-XXX Wear strips Previous The wear strips are designed to provide a fixed resistance to ensure that a single piece of paper is properly fed out of the media tray. There are several types of wear strips available for custom or hard to feed media. Media tray assembly Next Rear media guide...

  • Page 300: Sensor (Media Low)

    4062-XXX If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area Previous of the sensor (media empty). The sensor light is transmitted. When the sensing area is blocked (media is present), the signal is off.

  • Page 301: Layout Of Media Transport Path

    Previous Duplex Layout of media transport path The main components associated with the media path and transport with the duplex installed. Next Model T650 duplex paper path Go Back Standard bin full actuator and sensor (standard bin full) Sensor (input)

  • Page 302: Models T652 And T654 Duplex Paper Path

    4062-XXX Models T652 and T654 duplex paper path Previous Standard bin full actuator and sensor (standard bin full) Sensor (input) PC drum Next Diverter PC cartridge Go Back Sensor (fuser output) Sensor (narrow media) Sensor (option pass through) Sensor (duplex input) Pick arm assembly Functions of main components...

  • Page 303: Duplex Drive Motor Assembly

    4062-XXX Duplex drive motor assembly Previous 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. Duplex drive Next motor assembly Go Back Sensor (duplex input) 3-95 Diagnostic aids...

  • Page 304: Understanding Jam Numbers And Locations

    4062-XXX Previous 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 305: And 203 Paper Jams

    4062-XXX WARNING: Do not leave the cartridge exposed to light for extended periods. Previous WARNING: The jammed paper may be covered with unfused toner which can stain garments and skin. 5. Remove the jammed paper. CAUTION: The inside of the printer might be hot. To reduce the risk of injury from a hot component, Next allow the surface to cool before touching.

  • Page 306: Paper Jam

    4062-XXX 230 paper jam Previous Rear paper jams 1. Remove the standard tray from the printer. Next Go Back 2. Pull down the bottom rear door. 3-98 Service Manual...

  • Page 307: Front Paper Jams

    4062-XXX 3. Push the tab down. Previous Next Go Back 4. Remove the jammed paper. 5. Close the bottom rear door. 6. Insert the standard tray. 7. Press Front paper jams 1. Remove the standard tray from the printer. 2. Push the tab down. 3.

  • Page 308: Paper Jams (Optional External Duplex Unit)

    4062-XXX 231-239 paper jams (optional external duplex unit) Previous Rear paper jams 1. Push in and hold the latch while pulling up the rear duplex door. Next Go Back 2. Remove the jammed paper. 3. Close the rear duplex door. 4.

  • Page 309: Paper Jams

    4062-XXX 3. Raise the recessed duplex bar. Previous Next Go Back 4. Remove the jammed paper,. 5. Replace the duplex jam access tray. 6. Insert the standard tray. 7. Press 241–245 paper jams 1. Pull out the tray indicated on the display. 2.

  • Page 310: Paper Jam

    4062-XXX 250 paper jam Previous 1. Remove the paper from the multipurpose feeder. Next Go Back 2. Flex the sheets of paper back and forth to loosen them, and then fan them. Do not fold or crease the paper. Straighten the edges on a level surface. 3.

  • Page 311: Paper Jam

    4062-XXX 260 paper jam Previous The envelope feeder feeds envelopes from the bottom of the stack; the bottom envelope will be the one that is jammed. 1. Lift the envelope weight, and then remove all the envelopes. Next Go Back 2.

  • Page 312: Paper Jam

    4062-XXX 280 paper jam Previous 1. Pull down the StapleSmart II Finisher door. Next Go Back 2. Remove the jammed paper. 3. Close the StapleSmart ii Finisher door. 4. Press 3-104 Service Manual...

  • Page 313: Paper Jam

    4062-XXX 281 paper jam Previous 1. Clear the jam from the stapler output bin. Next Go Back 2. Press 282 paper jam To prevent paper jams, the stapler motor does not run when the stapler door is open. 1. Close the stapler door until it clicks into place. 2.

  • Page 314: Staple Jam

    4062-XXX 283 staple jam Previous 1. Press the latch to open the stapler door. Next Go Back 2. Pull the latch of the staple cartridge holder down, and then pull the holder out of the printer. 3. Use the metal tab to lift the staple guard, and then remove any loose staples. 3-106 Service Manual...
  • Page 315 4062-XXX 4. Press down on the staple guard until it snaps into place. Previous Next Go Back 5. Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place. 6. Close the stapler door. 7.

  • Page 316: Security Reset Jumper

    4062-XXX Previous Security Reset Jumper The Security Reset Jumper is available on all high-end printer and MFP models, including the T650, T652, T654, X652, X654, X656, and X658. It functions as described below (excerpt from the RIP Functional Spec): Next...
  • Page 317 4062-XXX 3. Remove the small yellow jumper that covers a pair of the jumper’s pins. Previous Next Go Back 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 318: Printer Skew Specifications

    LSU induced skew. If the horizontal line does not fall within the defined limit or spec, then it is considered skewed and the printhead must be adjusted. Go to “Polygon and Oscillating printhead mechanical registration adjustment” on page 4-2. Lexmark C544 Quick Test Printer Information Margin Settings Page Count...

  • Page 319: Print Registration

    4062-XXX Previous Duplex Skew Specification Side: Print Sequence Thru Printer: Next 16 lb-to-24 lb +/-0.007 mm/mm +/-0.005 mm/mm Go Back 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...
  • Page 320 4062-XXX Previous Next Go Back 3-112 Service Manual...

  • Page 321: Repair Information

    4062-XXX 4. Repair Information Previous WARNING: Read the following before handling electronic parts. Next Handling ESD-sensitive parts Go Back Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent damage to ESD-sensitive parts, follow the instructions below in addition to all the usual precautions, such as turning off power before removing logic boards: •...

  • Page 322: Adjustments

    4062-XXX Previous Adjustments Polygon and Oscillating printhead mechanical registration adjustment Do the printhead mechanically registration adjustment whenever you remove or replace the printhead or Next loosen the mounting screws. Install the new printhead with the mounting screws centered in the slots in the printhead frame assembly. Go Back Leave the screws loose enough to allow the printhead to move from side to side within the slots.

  • Page 323: Oscillating Printhead Assembly Electronic Adjustment

    5. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1. The Quick Previous Test Page consists of alignment diamonds, horizontal lines that can be used for mechanical registration adjustment. An example of the printhead alignment printout is shown below: Next Lexmark Hd Quick Test Device Information Go Back Page Cou nt...

  • Page 324: Alignment Assembly Adjustment

    4062-XXX alignment printout is shown below: Previous Next Lexmark Hd Quick Test Device Information Page Cou nt 192 MB Installed Memory Processor Speed 467MHz Go Back Serial Number 0116413 00 14 FF 00 00 00 00 TDS Calibration Engine ID...
  • Page 325 4062-XXX 1. Loosen the locknut on the inside rear of the alignment assembly. Previous 2. Remove the two screws holding the alignment assembly to the left side frame. 3. Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer.

  • Page 326: Fuser Solenoid Adjustment

    4062-XXX Step B Previous Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings should be within the range specified in “Registration” on page 3-67. The reference screw can be adjusted without loosening the locknut.

  • Page 327: Removals

    (C), or jamming will occur. Go to “Alignment assembly adjustment” on page 4-4. 1. Remove the side cover, left. Go to “Side cover, left removal (T650)” on page 4-64 “Side cover, left removal (T652, T654, T656)” on page 4-66.
  • Page 328 4062-XXX 2. Remove the six screws (A) securing the metal cover to the machine. Previous Next Go Back 3. Remove the metal cover. 4. Remove the inner deflector. Go to “Inner deflector removal” on page 4-24. 5. Remove the MPF pick solenoid assembly. Go to “MPF pick solenoid assembly removal”...
  • Page 329 4062-XXX 6. Remove the two screws (B) securing the alignment assembly to the machine. Previous Next Go Back 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 330: Connection Access Cover, Rear Removal

    2. Remove the connection access cover, rear. Connection bezel assembly, rear removal (T650) 1. Remove the side cover, left. Go to “Side cover, left removal (T650)” on page 4-64. 2. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on page 4-12.

  • Page 331: Connection Bezel Assembly, Rear Removal (T652, T654)

    4062-XXX Connection bezel assembly, rear removal (T652, T654) Previous 1. Remove the side cover, left. Go to “Side cover, left removal (T652, T654, T656)” on page 4-66. 2. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower (T652, T654)” on page 4-12.

  • Page 332: Cover Assembly, Rear Lower Removal (T650)

    4062-XXX Cover assembly, rear lower removal (T650) Previous 1. Remove the fuser access door assembly. Go to “Fuser access door assembly removal” on page 4-21. 2. Open the rear lower door. 3. Remove the three screws (A) securing the cover assembly, rear lower to the machine.

  • Page 333: Charge Roll Assembly Removal

    4062-XXX Charge roll assembly removal Previous WARNING: When removing the charge roll assembly, avoid touching the charge roll surface. 1. Open the MPF door assembly. 2. Open the operator panel front cover assembly. Next 3. Detach the left side of the charge roll assembly from the machine. Go Back 4.

  • Page 334: Door Assembly, Rear Removal

    4062-XXX Door assembly, rear removal Previous 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. Next 4.
  • Page 335 4062-XXX 6. Detach the rear duplex guide spring (C). Previous Next Go Back 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. 4-15 Repair Information...

  • Page 336: Duplex Assembly Removal (T652, T654, T656)

    4062-XXX Duplex assembly removal (T652, T654, T656) Previous 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.
  • Page 337 4062-XXX Duplex cooling fan removal (T652, T654, T656) Previous 1. Remove the side cover, right. See “Side cover, right removal (T652, T654, T656)” on page 4-67. 2. Remove the screw (A) securing the duplex cooling fan to the machine. 3. Disconnect the connector (B) from the duplex cooling fan. Next Go Back 4.
  • Page 338 4062-XXX Duplex drive motor assembly removal (T652, T654, T656) Previous 1. Remove the fuser access door. See “HVPS card assembly removal” on page 4-24. 2. Remove the cover assembly, rear lower. See “Cover assembly, rear lower (T652, T654)” on page 4-12.

  • Page 339: Duplex Input Sensor Assembly Removal (T652, T654, T656)

    4062-XXX 7. Remove the harness (E) from the duplex drive motor assembly. Previous Next Go Back Replacement Warning: When replacing the duplex drive motor assembly, ensure that all harnesses are properly re-routed. Replacement Note: Ensure the belt is replaced properly. Duplex input sensor assembly removal (T652, T654, T656) 1.

  • Page 340: Duplex Guide Assembly, Front Removal (T652, T654, T656)

    4062-XXX Duplex guide assembly, front removal (T652, T654, T656) Previous 1. Remove the media tray. 2. Gently place the printer on its left or right side. 3. Detach the front left duplex guide spring (A) from the duplex guide assembly, front. Next 4.

  • Page 341: Fuser Access Door Assembly Removal

    4062-XXX Fuser access door assembly removal Previous 1. Remove the door assembly, rear. Go to “Door assembly, rear removal” on page 4-14. 2. Press the two tabs (A) on the fuser access door assembly, and detach it from the machine. Next Go Back 4-21...

  • Page 342: Fuser Unit Assembly Removal

    4062-XXX 3. Swing the fuser access door assembly away from the machine. Previous 4. Unsnap the fuser access door assembly from the machine. 5. Remove the fuser access door assembly. Fuser drive release linkage removal Next 1. Remove the system card assembly. Go to “System card assembly removal”...

  • Page 343: Fuser Wiper Cover Assembly Removal

    4062-XXX 5. While pressing the two buttons (A), pull the fuser unit assembly from the machine. Previous Next Go Back 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 344: Inner Deflector Removal

    4062-XXX HVPS card assembly removal Previous 1. Remove the side cover, right. Go to “Side cover, right removal (T650)” on page 4-66 “Side cover, right removal (T652, T654, T656)” on page 4-67. 2. Remove the four screws (A) securing the HVPS card assembly to the machine.
  • Page 345 4062-XXX 2. Release the two hooks (A) securing the lower portion of the inner deflector to the machine. Previous Next Go Back 3. Remove the inner deflector. Replacement Warning: When replacing the inner deflector, ensure that it is properly installed, or jamming will occur.

  • Page 346: Laser Cover Removal

    2. Remove the fuser wiper cover assembly. Go to “Fuser wiper cover assembly removal” on page 4-23. 3. Remove the side cover, left. Go to “Side cover, left removal (T650)” on page 4-64 “Side cover, left Next removal (T652, T654, T656)” on page 4-66.

  • Page 347: Lcd Screen Bezel Removal (T650, T652, T654)

    4062-XXX 6. Remove the laser cover. Previous Next Go Back LCD screen bezel removal (T650, T652, T654) Gently detach the LCD screen bezel from the operator panel door assembly. 4-27 Repair Information...

  • Page 348: Lvps Card Assembly Removal (T650)

    “Door assembly, rear removal” on page 4-14. Next 2. Remove the side cover, right. Go to “Side cover, right removal (T650)” on page 4-66. 3. Disconnect the connector (A) from the LVPS card assembly. Go Back 4. Remove the two screws (B) from the LVPS card assembly.
  • Page 349 4062-XXX 6. Disconnect the connector (C) from the LVPS card assembly. Previous Next Go Back 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 350: Lvps Card Assembly Removal (T652, T654, T656)

    4062-XXX LVPS card assembly removal (T652, T654, T656) Previous WARNING: When replacing the LVPS card assembly, ensure that the voltage selection switch (E) is set to the proper setting, or damage will occur. 1. Remove the door assembly, rear. Go to “Door assembly, rear removal”...
  • Page 351 4062-XXX 6. Disconnect the connector (C) from the LVPS card assembly. Previous Next Go Back 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 352: Main Cooling Fan Removal

    4062-XXX Main cooling fan removal Previous 1. Remove the side cover, left assembly. Go to “MPF cam gear removal” on page 4-36 “Side cover, left removal (T652, T654, T656)” on page 4-66. 2. Remove the six screws (A) securing the metal shield to the machine. Next Go Back 3.

  • Page 353: Main Drive Motor Assembly Removal

    4062-XXX 7. Remove the fuser cooling fan connection (C). Previous Next Go Back Main drive motor assembly removal 1. Remove the system card assembly. Go to “System card assembly removal” on page 4-75. 2. Remove the fuser drive release linkage. Go to “Fuser drive release linkage removal”...

  • Page 354: Media Out Actuator Removal

    4062-XXX 6. Disconnect the connection (B) from the main drive motor assembly. Previous Next Go Back Replacement Warning: Ensure that all electrical connections are properly replaced. Replacement Warning: When replacing the main drive motor assembly, ensure that the operator panel door assembly is in the closed position or the main drive motor assembly will not align properly and damage will occur.

  • Page 355: Media Support Removal

    2. Remove the media support. Media turn guide removal 1. Remove the MPF tray door assembly. Go to “MPF tray door assembly removal (T650, T652, T654)” on page 4-40. 2. Gently bend the left side of the media turn guide to release the hook (A) as shown in the picture.

  • Page 356: Mpf Cam Gear Removal

    4062-XXX MPF cam gear removal Previous 1. Remove the alignment assembly. Go to “Output cover assembly removal” on page 4-53. 2. Release the hook (A) securing the gear to the unit. Next Go Back 3. Remove the MPF cam gear. MPF lift plate assembly removal 1.

  • Page 357: Mpf Media Out Actuator Removal

    4062-XXX 5. Remove the MPF lift plate assembly. Previous Replacement Warning: When replacing the MPF lift plate assembly, ensure that the lever (C) is held down when reinstalling the MPF lift plate assembly, or damage will occur. Replacement Warning: When replacing the MPF lift plate assembly, ensure that the MPF pick solenoid assembly does not become damaged.

  • Page 358: Mpf Pick Solenoid Assembly Removal

    4062-XXX MPF pick solenoid assembly removal Previous Note: The MPF lift plate assembly can be detached and allowed to hang by the harness. The connection does not need to be disconnected. 1. Remove the MPF lift plate assembly. Go to “MPF lift plate assembly removal”...
  • Page 359 4062-XXX 5. Remove the screw (B) securing the MPF pick solenoid assembly to the machine. Previous Next Go Back 6. Remove the MPF pick solenoid assembly. 7. Disconnect the connection (C) from the MPF pick solenoid assembly. 4-39 Repair Information...

  • Page 360: Mpf Tray Door Assembly Removal (T650, T652, T654)

    4062-XXX MPF tray door assembly removal (T650, T652, T654) Previous 1. Open the operator panel door assembly. 2. Open the MPF tray door assembly, and position it as shown in the picture. 3. Gently release the two bosses (A) from the slots (B).
  • Page 361 4062-XXX 4. While holding the MPF tray in its uppermost position, swing the MPF tray door assembly away from the Previous machine to detach the MPF tray from the machine. Next Go Back 4-41 Repair Information...

  • Page 362: Operator Panel Latch Assembly Removal (T650, T652, T654)

    Next Go Back 6. Remove the MPF tray door assembly. Operator panel latch assembly removal (T650, T652, T654) 1. Open the operator panel door assembly. 2. Remove the four screws (A) securing the operator panel latch assembly to the machine.

  • Page 363: Operator Panel Door Assembly Removal (T650, T652, T654)

    Previous Next Go Back 4. Remove the operator panel latch assembly. Operator panel door assembly removal (T650, T652, T654) Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second component listed above.

  • Page 364: Operator Panel Hinge Assembly, Left Removal (T650, T652, T654)

    6. Remove the two screws (C) securing the USB socket to the assembly. 7. Remove the USB socket. 8. Disconnect the connector (D) from the assembly. Operator panel hinge assembly, left removal (T650, T652, T654) 1. Remove the operator panel door assembly. Go to “Operator panel door assembly removal (T650, T652, T654)”...
  • Page 365 4062-XXX 5. Remove the harnesses (C) from the operator panel hinge assembly, left. Previous Next Go Back 6. Detach the spring (D) from the operator panel hinge assembly, left. 7. Detach the spring (E) from the operator panel hinge assembly, left. 8.

  • Page 366: Operator Panel Hinge Assembly, Right Removal (T650, T652, T654)

    10. Remove the operator panel hinge assembly, left. Previous Next Go Back Operator panel hinge assembly, right removal (T650, T652, T654) 1. Remove the operator panel door assembly. Go to “Operator panel door assembly removal (T650, T652, T654)” on page 4-43.
  • Page 367 4062-XXX 5. Remove the pin (D) from the operator panel hinge assembly, right. Previous Next Go Back 6. Remove the operator panel hinge assembly, right. 4-47 Repair Information...

  • Page 368: Operator Panel Door Assembly Removal (T656)

    4062-XXX Operator panel door assembly removal (T656) Previous Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second Next component listed above.
  • Page 369 4062-XXX 6. Remove eight screws (E) securing the scanner controller cage cover to the cage. An X658 model is Previous represented in the graphic below, however, the card cage cover removal procedure is similar for all models. Next Go Back 7.
  • Page 370 4062-XXX 9. Lift the operator panel door assembly out of the machine. Previous Next Go Back 4-50 Service Manual...

  • Page 371: Operator Panel Cover Latch Assembly Removal (T656)

    4062-XXX Operator panel cover latch assembly removal (T656) Previous 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. Next Go Back 3. Remove the operator panel cover latch assembly. Option drive shaft removal 1.
  • Page 372 4062-XXX 3. Remove the spring. Previous Next Go Back 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. 4-52 Service Manual...

  • Page 373: Output Cover Assembly Removal

    4062-XXX Output cover assembly removal Previous 1. Unsnap the output cover assembly from the machine. Next Go Back 2. Remove the output cover assembly. 4-53 Repair Information...

  • Page 374: Pick Arm Assembly Removal

    4062-XXX Pick arm assembly removal Previous 1. Remove the media tray from the machine. 2. Place the machine on the left or right side. 3. Remove the spring (A). Next 4. Remove the two E-clips (B) securing the pick arm assembly to the machine. Go Back 4-54 Service Manual...
  • Page 375 4062-XXX 5. Remove the screw (C) securing the pick arm assembly to the machine. Previous Next Go Back 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 376: 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. Go to “Side cover, right removal (T650)” on page 4-66 “Side cover, right removal (T652, T654, T656)” on page 4-67.

  • Page 377: Print Cartridge Clamp Assembly Removal

    4062-XXX Print cartridge clamp assembly removal Previous Note: This procedure can be applied to the left or right printer cartridge hold down assembly. 1. Remove the laser cover. Go to “Laser cover removal” on page 4-26. 2. Remove the screw (A) securing the print cartridge clamp assembly to the machine. Next Go Back 3.

  • Page 378: Print Cartridge Id Connector Assembly Removal

    4062-XXX Print cartridge ID connector assembly removal Previous 1. Remove the print cartridge. 2. Remove the main drive motor assembly. Go to “Output cover assembly removal” on page 4-53. 3. Release the two hooks (A) securing the print cartridge ID connector assembly to the machine. Next Go Back 4.

  • Page 379: Printhead Assembly Removal (T650)

    4062-XXX Printhead assembly removal (T650) Previous Note: When replacing the printhead assembly, ensure that the printhead is properly calibrated, or print quality issues will occur. Go to “Alignment assembly adjustment” on page 4-4. 1. Remove the laser cover. Go to “Laser cover removal”...

  • Page 380: Printhead Assembly Removal (T652, T654, T656)

    4062-XXX 5. Remove the three screws (C) securing the printhead assembly to the machine. Previous Next Go Back 6. Remove the printhead assembly. Replacement Warning: When replacing the printhead assembly, ensure that the printhead is properly calibrated, or print quality issues will occur. Printhead assembly removal (T652, T654, T656) WARNING: When replacing the printhead assembly, ensure that the printhead skew is properly adjusted, or print quality issues will occur.
  • Page 381 4062-XXX 3. Remove the metal cover. Previous 4. Disconnect the connections (B) from the printhead assembly. Next Go Back 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.

  • Page 382: Redrive Assembly Removal

    4062-XXX Redrive assembly removal Previous 1. Remove the door assembly, rear. Go to “Door assembly, rear removal” on page 4-14. 2. Open the fuser access door. 3. Remove the two screws (A) securing the redrive assembly to the machine. Next 4.
  • Page 383 4062-XXX 3. Remove the metal cover. Previous Next Go Back 4. Disconnect the connection (B) from the redrive motor assembly. 5. Disconnect the connection (C) from the sensor (standard media bin full). 4-63 Repair Information...

  • Page 384: Side Cover, Left Removal (T650)

    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. Side cover, left removal (T650) 1. Open the MPF tray door assembly. 2. Open the operator panel door assembly.
  • Page 385 4062-XXX 3. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on Previous page 4-12. 4. Remove the four screws (A) securing the side cover, left to the machine. Next Go Back 5. Swing the side cover, left away from the machine.

  • Page 386: Side Cover, Left Removal (T652, T654, T656)

    1. Open the MPF tray door assembly. 2. Open the operator panel door assembly. 3. Remove the cover assembly, rear lower. Go to “Cover assembly, rear lower removal (T650)” on Next page 4-12 “Cover assembly, rear lower (T652, T654)” on page 4-12.

  • Page 387: Side Cover, Right Removal (T652, T654, T656)

    4062-XXX 4. Remove the five screws (A) securing the side cover, right to the machine. Previous Next Go Back 5. Remove the side cover, right. Side cover, right removal (T652, T654, T656) 1. Open the operator panel door assembly. 2. Open the MPF tray door assembly. 3.

  • Page 388: Sensor (Duplex Input) Removal (T652, T654, T656)

    4062-XXX Sensor (duplex input) removal (T652, T654, T656) Previous 1. Remove the duplex input sensor assembly. Go to “Duplex input sensor assembly removal (T652, T654, T656)” on page 4-19. 2. Release the hooks (A) securing the senor (duplex media path) to the bracket. Next Go Back 3.

  • Page 389: Sensor (Media Level) Removal

    4062-XXX Sensor (media level) removal Previous 1. Remove the pick arm assembly. Go to “Pick arm assembly removal” on page 4-54. 2. Release the hooks (A) securing the sensor (media level) to the assembly. Next Go Back 3. Remove the sensor (media level). Sensor (media out) removal 1.

  • Page 390: Sensor (Toner Empty) Removal

    4062-XXX Sensor (toner empty) removal Previous 1. Remove the HVPS card assembly. Go to “HVPS card assembly removal” on page 4-24. 2. Remove the screw (A) securing the sensor (toner empty) to the machine. 3. Remove the sensor (toner empty). Next 4.

  • Page 391: Sensor Shield Assembly Removal

    4062-XXX Sensor shield assembly removal Previous 1. Remove the inner deflector. Go to “Inner deflector removal” on page 4-24. 2. Gently unsnap the sensor shield assembly from the machine. Next Go Back 3. Remove the sensor shield assembly. Replacement Warning: When replacing the sensor shield assembly, ensure that the spring (A) is properly aligned and the sensor shield assembly opens and closes properly.

  • Page 392: Sensor (Standard Bin Exit) Removal

    4062-XXX Sensor (standard bin exit) removal Previous 1. Remove standard bin actuator assembly. Go to “Sensor (standard bin exit) removal” on page 4-72. 2. Release the hooks (A) securing the sensor (standard bin exit) to the assembly. Next Go Back 3.

  • Page 393: Switch (Media Size) Assembly Removal

    4062-XXX 3. Press the tab (B) to release the standard bin actuator assembly from the machine. Previous Next Go Back 4. Remove the standard bin actuator assembly. Switch (media size) assembly removal 1. Remove the side cover, left. Go to “MPF cam gear removal”...
  • Page 394 4062-XXX 6. Release the two hooks (B) securing the switch (media size) assembly to the machine. Previous Next Go Back 7. Remove the switch (media size) assembly. 8. Disconnect the connection (C) from the switch (media size) assembly. 4-74 Service Manual...

  • Page 395: System Card Assembly Removal

    4062-XXX System card assembly removal Previous Warning: When replacing any of the following components: • Operator panel assembly • System card assembly Only replace one component at a time. Replace the required component and perform a POR before replacing a second Next component listed above.
  • Page 396 4062-XXX 4. Remove the metal shield. Previous Next Go Back 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 397 4062-XXX WARNING: When removing the system card assembly from the machine, ensure that the LVPS assembly Previous connection (C) does not become damaged. Next Go Back 7. Remove the system card assembly. 8. Remove any remaining screws securing the system card assembly to the metal box. 9.

  • Page 398: Nvm Card Assembly Removal

    NVM card assembly (T656 only) Next • System card assembly (All models) 1. Remove the side cover, left. Go to “Side cover, left removal (T650)” on page 4-64 “Side cover, left removal (T652, T654, T656)” on page 4-66. Go Back 2.
  • Page 399 4062-XXX 4. Remove the metal shield. Previous Next Go Back 5. Gently remove the NVM card assembly (B) from the machine. 4-79 Repair Information...

  • Page 400: Transfer Roll Assembly Removal

    4062-XXX Transfer roll assembly removal Previous 1. Open the operator panel door assembly. 2. Remove the print cartridge. 3. Gently unsnap the transfer roll assembly from the machine. Next Go Back 4. Remove the transfer roll assembly. Replacement Warning: When replacing the transfer roll assembly, do not touch the foam surface. Transfer roll bracket assembly, left removal 1.

  • Page 401: Transfer Roll Bracket Assembly, Right Removal

    4062-XXX 9. Remove the ground wire (F). Previous Next Go Back Replacement Warning: When reinstalling the transfer roll bracket assembly, left, ensure that the bushing (C), spring (D), and ground wire (F) are properly replaced. Transfer roll bracket assembly, right removal 1.

  • Page 402: Transfer Deflector Removal

    4062-XXX Transfer deflector removal Previous 1. Remove the transfer roll assembly. Go to “Transfer roll assembly removal” on page 4-80. 2. Gently unsnap the transfer deflector from the machine. 3. Remove the transfer deflector. Next 4. Remove the screw (A) securing the ground wire to the transfer deflector. Go Back 5.
  • Page 403 4062-XXX 3. Release the spring from the machine. Previous Next Go Back Note: The tray roller catch assembly should be removed from the media tray cabinet. 4. Remove the tray roller catch assembly from the machine. 4-83 Repair Information...

  • Page 404: Option Removals

    4062-XXX Previous Option removals 5-bin mailbox rear door assembly removal 1. Open the rear door assembly and twist the rear door strap vertical and remove the strap. Next Go Back 2. Pry the rear door hinges out of the bottom hinges and remove. 4-84 Service Manual...

  • Page 405: Bin Mailbox Left Outer Cover Removal

    4062-XXX 5-bin mailbox left outer cover removal Previous 1. Open the rear door assembly. 2. Grasp the upper rear corner of the left outer cover and pull it off the 5-bin mailbox assembly. Next Go Back 5-bin mailbox left inner cover removal 1.

  • Page 406: Bin Mailbox Right Outer Cover Removal

    4062-XXX 3. Remove the single screw (A) on the top and the four screws (B) on the inside of the left inner cover. Previous Next Go Back 4. Remove the 5-bin mailbox left inner cover. 5-bin mailbox right outer cover removal 1.

  • Page 407: Bin Mailbox Right Inner Cover Removal

    4062-XXX 5-bin mailbox right inner cover removal Previous 1. Remove the 5-bin mailbox rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. Remove the 5-bin mailbox right outer cover. Go to “5-bin mailbox right outer cover removal” on page 4-86.

  • Page 408: Bin Mailbox Top Cover Removal

    4062-XXX 5-bin mailbox top cover removal Previous 1. Open the rear door assembly. 2. Remove the cable cover panel by lifting up on the right side and pull to the right and out. Next Go Back 3. Remove the two screws (A) on each side of the top cover. 4.

  • Page 409: Bin Mailbox Media Bin Full Actuator Removal

    4062-XXX 5-bin mailbox media bin full actuator removal Previous 1. Remove the 5-bin mailbox left inner cover. Go to “5-bin mailbox left inner cover removal” on page 4-85. 2. Grasp the media bin full actuator and pull the pins from the bosses. Next Go Back 4-89...

  • Page 410: Bin Mailbox Sensor (Pass Through) Removal

    4062-XXX 5-bin mailbox sensor (pass through) removal Previous 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. If the lower pass through sensor needs to be removed, first remove the 5-bin mailbox rear door assembly. Go to “5-bin mailbox rear door assembly removal”...

  • Page 411: Bin Mailbox Sensor (Media Bin Empty) Removal

    4062-XXX 5-bin mailbox sensor (media bin empty) removal Previous 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Release the connecting tabs on the sensor (media bin empty) and remove from its bracket. Next Go Back 3.

  • Page 412: Bin Mailbox Controller Card Assembly Removal

    4062-XXX 5-bin mailbox controller card assembly removal Previous 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Disconnect all the harnesses from the 5-bin mailbox controller card assembly. 3. Remove the two screws (A) securing the controller card assembly to the 5-bin mailbox assembly. Next Go Back 4.

  • Page 413: Bin Mailbox Static Brush Mylar Assembly Removal

    4062-XXX 5-bin mailbox static brush mylar assembly removal Previous 1. Remove the 5-bin mailbox top cover. Go to “5-bin mailbox top cover removal” on page 4-88. 2. Carefully flex the 5-bin mailbox static brush mylar assembly to detach the hinges on each side. 3.

  • Page 414: Bin Mailbox Media Bin Fifth Deflector Removal

    4062-XXX 5-bin mailbox media bin fifth deflector removal Previous 1. Remove the rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. With a spring hook, carefully remove the upper deflector gate spring and for ease of reassembly, temp 3.

  • Page 415: Bin Mailbox Media Bin First Through Fourth Deflector Removal

    4062-XXX 5-bin mailbox media bin first through fourth deflector removal Previous 1. Remove the rear door assembly. Go to “5-bin mailbox rear door assembly removal” on page 4-84. 2. Using a springhook, remove the deflector spring from the deflector. Next Go Back 3.

  • Page 416: Bin Mailbox Media Bin Extension Assembly Removal

    4062-XXX 5-bin mailbox media bin extension assembly removal Previous 1. Fully extend the media bin extension. 2. Release the two tabs on the underside of the extension and pull out the rest of the way. 5-bin mailbox deflector gate solenoid removal Next 1.
  • Page 417 4062-XXX 4. Remove the screw (A) securing the appropriate 5-bin mailbox deflector gate solenoid. Previous Next Go Back 5. Remove and unroute the cable to the deflector gate solenoid. 6. Disconnect the proper deflector gate solenoid harness from the controller card. Note: To ease the cable unrouting, cut the appropriate cable.

  • Page 418: Bin Mailbox Transport Solenoid Removal

    4062-XXX 5-bin mailbox transport solenoid removal Previous 1. Remove the 5-bin mailbox left outer cover. Go to “5-bin mailbox left outer cover removal” on page 4-85. 2. Disconnect J15 at the controller card. 3. Remove the screw (A) securing the 5-bin mailbox transport solenoid to the left frame. Next Go Back 4.

  • Page 419: Bin Mailbox Sensor (Deflector Gate Hp) Removal

    4062-XXX 5-bin mailbox sensor (deflector gate HP) removal Previous 1. Remove the 5-bin left inner cover. Go to “5-bin mailbox left inner cover removal” on page 4-85. 2. Remove the following harnesses from the controller card: J14 A and B, J2, and J11. 3.
  • Page 420 4062-XXX 4. Remove the four screws (B) securing the left frame assembly to the 5-bin mailbox assembly. Previous Next Go Back 5. Move the left frame assembly out of the way. 6. Remove the 5-bin mailbox sensor (deflector gate HP) by pressing the tabs. 4-100 Service Manual...

  • Page 421: Sheet Option Tray Assembly

    4062-XXX 7. Disconnect the harness from the 5-bin mailbox sensor (deflector gate HP). Previous Next Go Back 250-sheet option tray assembly Note: Carefully remove the base machine from the input option tray assembly before proceeding. 4-101 Repair Information...

  • Page 422: Sheet Media Tray Assembly Removal

    4062-XXX 250-sheet media tray assembly removal Previous Note: This removal procedure can be applied to 250-sheet option drawer assembly. Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly. Next Go Back 250-sheet pick arm bracket assembly removal Note: Carefully remove the base machine from the input option tray assembly before proceeding.
  • Page 423 4062-XXX 3. Remove the three screws (A) securing the 250-sheet pick arm bracket assembly to the drawer. Previous Next Go Back 4. Remove the 250-sheet pick arm bracket assembly. 4-103 Repair Information...

  • Page 424: Sheet Media Out Actuator Removal

    4062-XXX 250-sheet media out actuator removal Previous Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Remove the 250-sheet pick arm bracket assembly. Go to “250-sheet pick arm bracket assembly removal” on page 4-102. Next 2.
  • Page 425 4062-XXX 4. Remove the four screws (A) securing the 250-sheet frame assembly to the drawer. Previous Next Go Back 5. Remove the 250-sheet frame assembly. 4-105 Repair Information...

  • Page 426: Sheet Controller Card Assembly Removal

    4062-XXX 250-sheet controller card assembly removal Previous 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Disconnect the three connectors from the 250-sheet controller card assembly. Next Go Back 3. Remove the three screws (B) securing the 250-sheet controller card assembly to the 250-sheet frame. 4.

  • Page 427: Sheet Option Tray Assembly

    4062-XXX 550-sheet option tray assembly Previous Next Go Back Note: Carefully remove the base machine from the input option tray assembly before proceeding. 550-sheet media tray assembly removal Note: This removal procedure can be applied to 550-sheet option drawer assembly. Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly.

  • Page 428: Sheet Pick Arm Bracket Assembly Removal

    4062-XXX 550-sheet pick arm bracket assembly removal Previous 1. Remove the 550-sheet media tray assembly. Go to “Media out actuator removal (models T652 and T654)” on page 4-159. 2. Remove the two 550-sheet pick arm bracket assembly cable connectors (A) from the 550-sheet controller card assembly.

  • Page 429: Sheet Bellcrank Recoil Spring Removal

    4062-XXX 550-sheet bellcrank recoil spring removal Previous 1. Remove the 550-sheet pick arm bracket assembly. Go to “550-sheet pick arm bracket assembly removal” on page 4-108. 2. Remove the 550-sheet bellcrank recoil spring from the 550-sheet pick arm bracket assembly. Next Go Back 4-109...

  • Page 430: Sheet Frame Assembly Removal

    4062-XXX 550-sheet frame assembly removal Previous Note: The 550-sheet frame assembly is not a FRU. 1. Remove the 550-sheet pick arm bracket assembly. Go to “550-sheet pick arm bracket assembly removal” on page 4-108. Next 2. Release the hooks securing the sensor (pass through) to the drawer. 3.

  • Page 431: Sheet Controller Card Assembly Removal

    4062-XXX 5. Remove the 550-sheet frame assembly. Previous Next Go Back 550-sheet controller card assembly removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-160. 2. Disconnect the three connectors from the 550-sheet controller card assembly. 4-111 Repair Information...
  • Page 432 4062-XXX 3. Remove the three screws (A) securing the 550-sheet controller card assembly to the 550-sheet frame. Previous Next Go Back 4. Remove the 550-sheet controller card assembly. 4-112 Service Manual...

  • Page 433: Sheet Option Drive Shaft With Spring Removal

    4062-XXX 550-sheet option drive shaft with spring removal Previous 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-160. 2. Pinch the two hooks (A) on the cap, and detach it from the 550-sheet frame. 3.

  • Page 434: High Capacity Input Tray (Hcit)

    4062-XXX 2. Turn the drawer upside down, and unsnap the two hooks (A) securing the anti-tip latch assembly to the Previous drawer with a flathead screwdriver. Note: The hooks might break when detaching the anti-tip assembly from the drawer. Next Go Back 3.

  • Page 435: High Capacity Input Tray (Hcit) Media Tray Assembly Removal

    4062-XXX High capacity input tray (HCIT) media tray assembly removal Previous 1. Open the HCIT media tray assembly until it reaches a stop. 2. Press the latches (A) on the left and right sides of the HCIT tray slides. Next Go Back 3.

  • Page 436: High Capacity Input Tray (Hcit) Tray Cover, Front Removal

    4062-XXX High capacity input tray (HCIT) tray cover, front removal Previous 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. Next Go Back 4-116...
  • Page 437 4062-XXX Previous Next Go Back 3. Remove the HCIT tray cover, front. 4-117 Repair Information...

  • Page 438: High Capacity Input Tray (Hcit) Cover, Rear Removal

    4062-XXX High capacity input tray (HCIT) cover, rear removal Previous 1. Remove the HCIT media tray assembly. Go to “High capacity input tray (HCIT) media tray assembly removal” on page 4-115. 2. Remove the four screws (A) securing the HCIT cover, rear to the drawer. Next Go Back 4-118...
  • Page 439 4062-XXX 3. Remove the HCIT cover, rear. Previous Next Go Back 4-119 Repair Information...

  • Page 440: High Capacity Input Tray (Hcit) Cover, Right Removal

    4062-XXX High capacity input tray (HCIT) cover, right removal Previous Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. Note: Before removing the HCIT right cover, first remove the right side anti-tip latch assembly. Go to “High capacity input tray (HCIT) anti-tip latch assembly removal”...
  • Page 441 4062-XXX Previous Next Go Back 3. Remove the HCIT cover, right. 4-121 Repair Information...

  • Page 442: High Capacity Input Tray (Hcit) Cover, Left Removal

    4062-XXX High capacity input tray (HCIT) cover, left removal Previous Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. Note: Before removing the HCIT cover, left, first remove the left side anti-tip latch assembly. Go to “High capacity input tray (HCIT) anti-tip latch assembly removal”...

  • Page 443: High Capacity Input Tray (Hcit) Anti-Tip Latch Assembly Removal

    4062-XXX Previous Next Go Back 3. Remove the HCIT cover, left. High capacity input tray (HCIT) anti-tip latch assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. The left and right anti-tip latch assemblies are the same, and only one is in a package. The instructions below are for removing the left latch;...

  • Page 444: High Capacity Input Tray (Hcit) Drawer Slide Assembly Removal

    4062-XXX 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on Previous page 4-122. Note: The left side anti-tip assembly will come off when removing the HCIT cover, left. Next Go Back 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.

  • Page 445: High Capacity Input Tray (Hcit) Tray Lift Drive Motor Assembly Removal

    4062-XXX 2. Remove the three screws (A) securing the HCIT drawer slide to the frame of the drawer. Previous Next Go Back 3. Remove the HCIT drawer slide. High capacity input tray (HCIT) tray lift drive motor assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1.

  • Page 446: High Capacity Input Tray (Hcit) Controller Card Assembly Removal

    4062-XXX 4. Remove the eight screws (A) securing the HCIT tray lift drive motor assembly. Previous Next Go Back 5. Remove the HCIT tray lift drive motor assembly. High capacity input tray (HCIT) controller card assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1.
  • Page 447 4062-XXX 2. Disconnect all connectors from the HCIT controller card assembly. Previous Next Go Back 3. Remove the three screws (A) securing the HCIT controller card assembly. 4. Remove the HCIT controller card assembly and the shield. 4-127 Repair Information...

  • Page 448: High Capacity Input Tray (Hcit) Media Size Actuator Assembly Removal

    4062-XXX High capacity input tray (HCIT) media size actuator assembly removal Previous Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT controller card assembly. Go to “High capacity input tray (HCIT) controller card assembly removal”...
  • Page 449 4062-XXX 5. Remove the four screws (D) securing the card mount option with the media size actuator to the frame. Previous Next Go Back 4-129 Repair Information...
  • Page 450 4062-XXX 6. Remove the card mount option with the media size actuator. Previous Re-installation note: 1. Re-install the card mount option with the media size actuator to the frame by inserting the leftmost part of it through the hole, and then securing it with the four screws. Next 2.

  • Page 451: High Capacity Input Tray (Hcit) Pick Arm Bracket Assembly Removal

    4062-XXX High capacity input tray (HCIT) pick arm bracket assembly removal Previous Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122.
  • Page 452 4062-XXX 4. Remove the five screws (A) securing the HCIT pick arm bracket assembly. Previous Next Go Back 5. Remove the HCIT pick arm bracket assembly from the drawer by slightly lifting and removing it. 4-132 Service Manual...

  • Page 453: High Capacity Input Tray (Hcit) Tray Closed Latch With Spring Removal

    4062-XXX High capacity input tray (HCIT) tray closed latch with spring removal Previous 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 454: High Capacity Stacker Rear Door Assembly Removal

    4062-XXX High capacity stacker rear door assembly removal Previous 1. Open the rear door assembly. 2. Remove the rear door strap by twisting vertically and pulling it out of the slot. 3. Remove the rear door assembly from the hinges by gently prying the hinges off the bosses. Next Go Back 4-134...

  • Page 455: High Capacity Stacker Right Cover Removal

    4062-XXX High capacity stacker right cover removal Previous 1. Remove the high capacity stacker rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-134. 2. Using a #1 phillips screwdriver, remove the three screws (A) securing the right cover to the high capacity stacker assembly.

  • Page 456: High Capacity Stacker Left Cover Removal

    4062-XXX High capacity stacker left cover removal Previous 1. Remove the high capacity stacker rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-134. 2. Using a #1 phillips screwdriver, remove the three screws (A) securing the left cover to the high capacity stacker assembly.

  • Page 457: High Capacity Stacker Media Output Bin Assembly Removal

    4062-XXX High capacity stacker media output bin assembly removal Previous 1. Remove both the high capacity stacker media output bin recoil springs. 2. Remove the high capacity stacker standard output bin LED. 3. Carefully spread the left side of the high capacity stacker assembly and maneuver the media output bin Next from the assembly.

  • Page 458: High Capacity Stacker Controller Card Cover Panel Removal

    4062-XXX High capacity stacker controller card cover panel removal Previous 1. Remove the media output bin assembly. Go to “High capacity stacker media output bin assembly removal” on page 4-137. 2. Remove the two screws (A) securing the controller card cover panel on the rear of the assembly. Next 3.

  • Page 459: High Capacity Stacker Switch (Media Bin Hp) Removal

    4062-XXX High capacity stacker switch (media bin HP) removal Previous 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-138. 2. Remove the two screws (A) securing the high capacity stacker switch (media bin HP) to the left frame. Next Go Back 3.

  • Page 460: High Capacity Stacker Sensor (Media Bin Full) Assembly Removal

    4062-XXX High capacity stacker sensor (media bin full) assembly removal Previous 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal” on page 4-138. 2. Release the tabs securing the high capacity stacker sensor (media bin full) assembly to the left frame. Next 3.

  • Page 461: High Capacity Stacker Controller Card Assembly (Upper And Lower) Removal

    4062-XXX 3. Remove the bracket from the frame and disconnect the sensor (media bin full) and media bin full actuator. Previous High capacity stacker controller card assembly (upper and lower) removal 1. Remove the high capacity stacker controller card cover panel. Go to “High capacity stacker controller card cover panel removal”...

  • Page 462: High Capacity Stacker Right Frame Removal

    4062-XXX High capacity stacker right frame removal Previous 1. Remove the right media output bin recoil spring. 2. Remove the four screws (A) securing the right frame to the high capacity stacker assembly. 3. Carefully remove the right frame. Next Go Back Note: When installing the right frame, make sure the media output bin assembly is aligned properly.

  • Page 463: High Capacity Stacker Left Frame Removal

    4062-XXX High capacity stacker left frame removal Previous 1. Remove the left media output bin recoil spring. 2. Remove the two screws (A) securing the switch (media bin HP) to the left frame. 3. Remove the high capacity stacker standard output bin LED. Next 4.

  • Page 464: High Capacity Stacker Upper Deflector Gate Removal

    4062-XXX Note: When installing the left frame, make sure the media output bin assembly is aligned properly. Previous High capacity stacker upper deflector gate removal 1. Remove the rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-134.

  • Page 465: High Capacity Stacker Sensor (Pass Through) Removal

    4062-XXX 3. Unsnap each side of the deflector gate and remove. Previous Next Go Back High capacity stacker sensor (pass through) removal 1. Remove the rear door assembly. Go to “High capacity stacker rear door assembly removal” on page 4-134. 2.
  • Page 466 4062-XXX 4. Disconnect the sensor (pass through) harness from the controller card and remove the sensor. Previous Next Go Back 4-146 Service Manual...

  • Page 467: High Capacity Stacker Left Mounting Bracket Removal

    4062-XXX High capacity stacker left mounting bracket removal Previous 1. Remove the high capacity stacker left cover. “High capacity stacker left cover removal” on page 4-136. 2. Remove the eight screws (A) securing the high capacity stacker left mounting bracket. Next Go Back 3.

  • Page 468: High Capacity Stacker Sensor (Deflector Gate Hp) Removal

    4062-XXX High capacity stacker sensor (deflector gate HP) removal Previous 1. Remove the high capacity stacker left mounting bracket. Go to “High capacity stacker left mounting bracket removal” on page 4-147. 2. Remove the harness from the sensor. Next 3. Unclip the sensor tabs and remove. Go Back 4-148 Service Manual...
  • Page 469 4062-XXX Installing / Removing the RFID UHF option Previous 1. RFID UHF option components: 1. RFID UHF Option 2. Firmware card 3. User Flash card Next 4. Fuser wiper 5. Interface card, plastic tee, screw 6. RFID cable Go Back 7.
  • Page 470 4062-XXX 3. Open the system board door, and loosen the screw on the system board cover. Remove the cover. Previous Next Go Back 4. Install the firmware card into the system board. 4-150 Service Manual...
  • Page 471 4062-XXX 5. Install the flash card into the system board. Previous Next Go Back 4-151 Repair Information...
  • Page 472 4062-XXX 6. Remove the metal cover from the system card opening. Previous Next Go Back 7. Locate the interface card mounting area on the system board. 4-152 Service Manual...
  • Page 473 4062-XXX 8. Snap the plastic tee card holder into place on the system board. Previous Next Go Back 9. Angle the interface card through the connector opening. 10. Insert the interface card into the plastic tee card holder. 4-153 Repair Information...
  • Page 474 4062-XXX 11. Insert the long thumbscrew into the hole in the interface card. Turn it just enough to hold the card in place. Previous Do not tighten yet. Next Go Back 12. Insert the screws to secure the mounting bracket to the system board. 13.
  • Page 475 4062-XXX 14. Replace the system board cover. Previous Next Go Back 15. Lift the printer off the 250/550 sheet optional drawer, place the RFID option on top of the drawer, and place the printer on top of the RFID option. 4-155 Repair Information...
  • Page 476 4062-XXX 16. Unpack the RFID cable, and attach between the RFID option and the interface card. Reconnect all printer Previous cables. Next Go Back 17. Remove the old fuser wiper (or blank). 4-156 Service Manual...

  • Page 477: Lower Interface Cable Assembly Removal

    4062-XXX 18. Install the new wiper. Turn the printer on. Previous Next Go Back 19. To remove the RFID UHF option, reverse the order of installation. Lower interface cable assembly removal 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-160.

  • Page 478: Media Size Actuator Removal

    4062-XXX Media size actuator removal Previous Note: Carefully remove the base machine from the input option tray assembly before proceeding. 1. Remove the 250-sheet controller card assembly. Go to “250-sheet controller card assembly removal” on page 4-106. Next 2. Remove the screw (A) securing the media size actuator to the 250-sheet frame. Go Back 3.

  • Page 479: Media Out Actuator Removal (Models T652 And T654)

    4062-XXX Media tray catch spring removal Previous 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Turn the drawer upside down to access the media tray catch spring. 3. Release the media tray catch spring. Next Go Back Media out actuator removal (models T652 and T654)

  • Page 480: Media Size Actuator Removal

    4062-XXX Media size actuator removal Previous 1. Remove the 550-sheet controller card assembly. Go to “550-sheet controller card assembly removal” on page 4-111. 2. Remove the screw (A) securing the media size actuator to the 550-sheet frame. Next Go Back 3.
  • Page 481 4062-XXX 1. Remove the media tray catch spring. Go to “Media tray catch spring removal” on page 4-160. Previous 2. Remove the tray roller catch assembly from the drawer. Next Go Back 4-161 Repair Information...

  • Page 482: Output Expander Rear Door Assembly Removal

    4062-XXX Output expander rear door assembly removal Previous 1. Open the rear door assembly. 2. Hold the door to approximately 45° angle, and force out the left hinge and slide the right hinge out to remove the door. Next Go Back Output expander left outer cover removal 1.

  • Page 483: Output Expander Left Inner Cover Removal

    4062-XXX Output expander left inner cover removal Previous 1. Remove the output expander left outer cover. Go to “Output expander left outer cover removal” on page 4-162. 2. Remove the screw (A) securing the left inner cover. Next Go Back 3.

  • Page 484: Output Expander Right Inner Cover Removal

    4062-XXX Output expander right inner cover removal Previous 1. Remove the output expander right outer cover. Go to “Output expander right outer cover removal” on page 4-163. 2. Remove the screw (A) securing the right inner cover to the unit. Next Go Back 3.

  • Page 485: Output Expander Media Output Bin Assembly Removal

    4062-XXX Output expander media output bin assembly removal Previous 1. Remove the left and right output expander media bin latches. Go to “Output expander media bin latch (left and right) removal” on page 4-164. 2. Remove the standard output bin LED. Go to “Output expander sensor (pass through) removal”...

  • Page 486: Output Expander Sensors (Media Bin Full) Assembly Removal

    4062-XXX Output expander sensors (media bin full) assembly removal Previous 1. Remove the output bin left inner cover. Go to “Output expander left inner cover removal” on page 4-163. 2. Untwist the sensor harnesses from the cable guide. Next 3. Release the tabs securing the sensors (media bin full) and remove. Replacement Note: Be sure to replace the sensors in the correct order.

  • Page 487: Output Expander Sensor (Media Bin Full) Bracket Assembly Removal

    4062-XXX Output expander sensor (media bin full) bracket assembly removal Previous 1. Remove the output expander left inner cover. Go to “Output expander left inner cover removal” on page 4-163. 2. Grasp the sensor bracket and pull away from the option while releasing the tab. Next Go Back 3.
  • Page 488 4062-XXX 2. Remove the screw (A) on the back side of the option. Previous Next Go Back 3. Remove the grounding screw (B) on the right output option frame guide the grounding cable through the hole in the frame. 4. Carefully flex the panel from the lower middle and pull the four tab (C) out of the frame and remove. 4-168 Service Manual...

  • Page 489: Output Expander Controller Card Removal

    4062-XXX Output expander controller card removal Previous 1. Remove the output expander controller card cover panel. Go to “Output expander controller card cover panel removal” on page 4-167. 2. Disconnect all harnesses from the controller card. Next 3. Remove the two screws (A) securing the controller card to the frame. Go Back 4.

  • Page 490: Output Expander Sensor (Pass Through) Removal

    4062-XXX Output expander sensor (pass through) removal Previous 1. Remove the output expander controller card cover panel. Go to “Output expander controller card cover panel removal” on page 4-167. 2. Release the tabs securing the sensor (pass through). Next 3. Remove the sensor harness from the controller card. 4.

  • Page 491: Output Expander Deflector Gate Removal

    4062-XXX Output expander deflector gate removal Previous 1. Use a spring hook to disconnect the upper end of the deflector gate spring. 2. Temporarily hook the upper end of the deflector gate spring to the left frame. 3. Pull the deflector gate out of its hinges and remove. Next Go Back 4-171...

  • Page 492: Output Expander Sensor (Deflector Gate Hp) Removal

    4062-XXX Output expander sensor (deflector gate HP) removal Previous 1. Remove the output expander left inner cover. Go to “Output expander left inner cover removal” on page 4-163. 2. Remove the four screws securing the left frame assembly to the option. Next 3.

  • Page 493: Sfp Stapler Assembly Rear Door Assembly Removal

    4062-XXX SFP stapler assembly rear door assembly removal Previous 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. Next 4.

  • Page 494: Sfp Stapler Assembly Left Cover Removal

    4062-XXX SFP stapler assembly left cover removal Previous 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. Next Go Back 2. Pull out on the front side of the left cover to disengage the tabs. 3.

  • Page 495: Sfp Stapler Assembly Top Cover Removal

    4062-XXX SFP stapler assembly top cover removal Previous 1. Remove the left and right cover. Go to “SFP stapler assembly left cover removal” on page 4-174 “SFP stapler assembly right cover removal” on page 4-173. 2. Remove the two screws (A) from the left and right side of the top cover. Next Go Back 3.

  • Page 496: Sfp Stapler Assembly Handle Cover Removal

    4062-XXX SFP stapler assembly handle cover removal Previous 1. Remove the left and right cover. Go to “SFP stapler assembly left cover removal” on page 4-174 “SFP stapler assembly right cover removal” on page 4-173. 2. Remove two screws (A) from each side of the SFP stapler assembly. Next Go Back 3.

  • Page 497: Sfp Stapler Assembly Led Sensor Cover Removal

    4062-XXX SFP stapler assembly LED sensor cover removal Previous 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. Next Go Back 2. Remove the output bin LED. Go to “SFP stapler assembly standard output bin LED and LED clear lens removal”...

  • Page 498: Sfp Stapler Assembly Sensor (Finisher Bin Media Present) Removal

    4062-XXX 4. Remove the LED sensor cover. Previous Next Go Back SFP stapler assembly sensor (finisher bin media present) removal 1. Remove the LED sensor cover. Go to “SFP stapler assembly LED sensor cover removal” on page 4-177. 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. 3.

  • Page 499: Sfp Stapler Assembly Standard Output Bin Led And Led Clear Lens Removal

    4062-XXX SFP stapler assembly standard output bin LED and LED clear lens removal Previous 1. Remove the LED sensor cover. Go to “SFP stapler assembly LED sensor cover removal” on page 4-177. 2. Remove the two screws (A) securing the LED to the cover. Next Go Back 3.

  • Page 500: Sfp Stapler Assembly Tamper Drive Belt Removal

    4062-XXX SFP stapler assembly tamper drive belt removal Previous 1. Remove the tamper recoil spring. Go to “SFP stapler assembly tamper drive belt removal” on page 4-180. 2. Pull the belt out the tamper belt holder and remove the belt from the pulley. Next Go Back 4-180...

  • Page 501: Sfp Stapler Assembly Tamper Drive Motor Assembly Removal

    4062-XXX SFP stapler assembly tamper drive motor assembly removal Previous 1. Remove the top cover. Go to “SFP stapler assembly top cover removal” on page 4-175. 2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley. 3.

  • Page 502: Sfp Stapler Assembly Media Stack Flap And Media Stack Flap Actuator Removal

    4062-XXX SFP stapler assembly media stack flap and media stack flap actuator removal Previous 1. Remove the handle cover. Go to “SFP stapler assembly handle cover removal” on page 4-176. 2. Release the locking tab and slide the media stack flap actuator to the right and remove. Next Go Back 4-182...

  • Page 503: Sfp Stapler Assembly Stapler Unit Assembly Removal

    4062-XXX SFP stapler assembly stapler unit assembly removal Previous 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-173. 2. Remove the four cable harnesses attached to the stapler unit assembly. 3. Remove the three screws (A) securing the stapler unit assembly. Next Go Back 4.

  • Page 504: Sfp Stapler Assembly Paddle Drive Motor Assembly Removal

    4062-XXX SFP stapler assembly paddle drive motor assembly removal Previous 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-174. 2. Disconnect the paddle motor harness from the controller card. 3. Remove the cable from the harness clip. Next 4.

  • Page 505: Sfp Stapler Assembly Sensor (Media Stack) Removal

    4062-XXX SFP stapler assembly sensor (media stack) removal Previous 1. Remove the top cover. Go to “SFP stapler assembly top cover removal” on page 4-175. 2. Disconnect the harness to the sensor (media stack). 3. Using your fingers, pinch tab (A) securing the sensor (media stack) and remove. Next Go Back 4-185...

  • Page 506: Sfp Stapler Assembly Sensor (Paddle Hp) Removal

    4062-XXX SFP stapler assembly sensor (paddle HP) removal Previous 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-174. 2. Disconnect the harness to the sensor (paddle home position). 3. Using your fingers, pinch tab (A) securing the sensor (paddle home position) and remove. Next Go Back 4-186...

  • Page 507: Sfp Stapler Assembly Sensor (Stapler Access Door Interlock) Removal

    4062-XXX SFP stapler assembly sensor (stapler access door interlock) removal Previous 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-173. 2. Disconnect the harness to the sensor (stapler access door interlock). 3. Using your fingers, pinch tab (A) securing the sensor (stapler access door interlock) and remove. Next Go Back 4-187...

  • Page 508: Sfp Stapler Assembly Sensor (Tamper Hp Left And Right) Removal

    4062-XXX SFP stapler assembly sensor (tamper HP left and right) removal Previous 1. Remove the SFP stapler assembly top cover. Go to “SFP stapler assembly top cover removal” on page 4-175. 2. Disconnect the harness to the SFP stapler assembly sensor (tamper HP left and right). Next 3.

  • Page 509: Sfp Stapler Assembly Sensor (Bin Full Send) Removal

    4062-XXX SFP stapler assembly sensor (bin full send) removal Previous 1. Remove the stapler/stacker controller card assembly. Go to “Stapler/stacker controller card assembly removal” on page 4-193. 2. Remove the two screws (A) securing the staple finisher sensor (bin full send). Next Go Back 3.

  • Page 510: Sfp Stapler Assembly Sensor (Bin Full Receive) Removal

    4062-XXX SFP stapler assembly sensor (bin full receive) removal Previous 1. Remove the right cover. Go to “SFP stapler assembly right cover removal” on page 4-173. 2. Remove the two screws (A) securing the sensor (bin full receive). Next Go Back 3.

  • Page 511: Sfp Stapler Assembly Sensor (Deflector Hp) Removal

    4062-XXX 3. Using needlenose pliers, carefully grip the sensor and pull it out and disconnect the harness. Previous Next Go Back Replacement Notes: Using needlenose pliers, place the rear most tab in the sensor bracket first. Then push on the rear face of the sensor until the other two tabs snap into place. SFP stapler assembly sensor (deflector HP) removal 1.
  • Page 512 4062-XXX 3. Release the tabs (A) securing the sensor to the unit. Previous Next Go Back Note: The tabs may be difficult to access. The use of a spring hook or flat-blade screwdriver may be necessary to release the tabs. 4-192 Service Manual...

  • Page 513: Stapler/Stacker Controller Card Assembly Removal

    4062-XXX Stapler/stacker controller card assembly removal Previous 1. Remove the left cover. Go to “SFP stapler assembly left cover removal” on page 4-174. 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. Next Go Back 4.
  • Page 514 4062-XXX 2. Disconnect the sensor (HCIT tray raised HP) cable connector from the HCIT controller card assembly. Previous Next Go Back Note: Remove the cable from the restraints, and observe the routing for reinstallation. 4-194 Service Manual...
  • Page 515 4062-XXX 3. Remove the screw (A) securing the sensor to the rear frame. Previous 4. Release the hooks (B) securing the sensor to the rear frame. Next Go Back 5. Remove the sensor (HCIT tray raised HP). 4-195 Repair Information...

  • Page 516: Sensor (Hcit Pass Through) With Cable Removal

    4062-XXX Sensor (HCIT pass through) with cable removal Previous Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 1. Remove the HCIT cover, left. Go to “High capacity input tray (HCIT) cover, left removal” on page 4-122.

  • Page 517: Sensor (Pass Through) With Cable Removal

    4062-XXX Sensor (pass through) with cable removal Previous 1. Remove the 250-sheet frame assembly. Go to “250-sheet frame assembly removal” on page 4-104. 2. Disconnect the sensor (pass through) cable connector from the 250-sheet controller card. 3. Remove the sensor (pass through) with cable. Next Go Back Sensor (pass through) with cable removal...

  • Page 518: Tray Roller Catch Assembly Removal

    4062-XXX 2. Remove the tray roller catch assembly from the drawer. Previous Next Go Back Tray roller catch assembly removal 1. Remove the media tray catch spring. Go to “Media tray catch spring removal” on page 4-159. 2. Remove the tray roller catch assembly from the drawer. 4-198 Service Manual...

  • Page 519: Upper Interface Cable Assembly Removal

    4062-XXX Upper interface cable assembly removal Previous 1. Remove the 550-sheet frame assembly. Go to “Media size actuator removal” on page 4-160. 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. Next Go Back 4.
  • Page 520 4062-XXX Previous Next Go Back 4-200 Service Manual...

  • Page 521: Connector Locations And Connections

    4062-XXX 5. Connector locations and connections Previous Connections Next Go to the Wiring diagram section at the last part of this manual. Go Back Connector locations and connections...
  • Page 522 4062-XXX Previous Next Go Back Service Manual...

  • Page 523: Preventive Maintenance

    Damaged, missing, or altered parts, especially in the area of the on/off switch and the power supply. • Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover. • Possible safety exposure from any non-Lexmark attachments. Lubrication specifications No requirements for this printer. Individual maintenance part expected life...

  • Page 524: Scheduled Maintenance

    4062-XXX Previous Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at required maintenance intervals. It is Next necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and reliability of the printer.

  • Page 525: Parts Catalog

    4062-XXX 7. Parts catalog Previous How to use this parts catalog Next The following legend is used in the parts catalog: Units/mach Units/ Go Back Asm- Part - OR - kit or Description Index number Units/option • Asm-index: identifies the assembly and the item in the diagram. For example, 3-1 indicates Assembly 3 and the item number 1.

  • Page 526: Assembly 1: Covers

    4062-XXX Assembly 1: Covers Previous Next Go Back Service Manual...
  • Page 527 Connection bezel assembly, rear (T650) 40X4629 Connection bezel assembly, rear (T652, T654, and T656) 40X4320 Laser cover assembly, 250 sheet output (T650 and T652) 40X4321 Laser cover assembly, 500 sheet output (T654) 40X7031 Laser cover assembly, 500 sheet output (T656)

  • Page 528: Assembly 2: T650, T652, And T654 Operator Panel

    4062-XXX Assembly 2: T650, T652, and T654 Operator panel Previous Next Go Back Service Manual...
  • Page 529 Operator panel hinge assembly, right (T650, T652, and T654) Go Back 40X4616 Operator panel latch assembly (T650, T652, and T654) 40X4396 Operator panel hinge assembly with interlock switch, left (T650, T652, and T654) 40X4415 LCD screen bezel (T650n) 40X4494 LCD screen bezel (T652n)

  • Page 530: Assembly 3: T656Dne Operator Panel, Mpf And Smart Card

    4062-XXX Assembly 3: T656dne Operator panel, MPF and smart card Previous Next Go Back Service Manual...
  • Page 531 4062-XXX Assembly 3: T656 Operator panel, MPF and smart card Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X7039 Card reader cable assembly (T656) 40X1972 Inner cover, right (T656) Next 40X2045 Operator panel cable assembly (T656) 40X2089 MPF tray door assembly (T656) Go Back...

  • Page 532: Assembly 4: Drive Motor Assemblies And Duplex

    4062-XXX Assembly 4: Drive motor assemblies and duplex Previous Next Go Back Service Manual...
  • Page 533 Duplex drive belt, lower (T652, T654, and T656) 40X4354 Duplex drive belt, upper (T652, T654, and T656) 40X4302 Aligner assembly with ground strap and adj. screw (T650) 40X4303 Aligner assembly with ground strap and adj. screw (T652, T654, and T656) 40X1863...

  • Page 534: Assembly 5: Media Path And Ducts

    4062-XXX Assembly 5: Media path and ducts Previous Next Go Back 7-10 Service Manual...
  • Page 535 40X1868 Print cartridge clamp assembly 40X4389 LVPS cooling duct 40X4391 Main cooling duct (T650) 40X4392 Main cooling duct (T652, T654, and T656) 40X4319 Fuser access door assembly (T650) 40X4318 Fuser access door assembly (T652, T654, and T656) 7-11 Parts catalog...

  • Page 536: Assembly 6: Printhead, Charge, And Transfer

    4062-XXX Assembly 6: Printhead, charge, and transfer Previous Next Go Back 7-12 Service Manual...
  • Page 537 Printhead with cable assembly (T652 and T654) 40X7040 Printhead with cable assembly (T656) Next 40X1865 Printhead cable (T652, T654, and T656) 40X4463 Printhead with cable assembly (T650) Go Back 40X4367 Printhead cable assembly (T650) 40X4317 Charge roll link spring, right 40X1893...

  • Page 538: Assembly 7: Pick Arm Assembly, Trays, And Mpf

    4062-XXX Assembly 7: Pick arm assembly, trays, and MPF Previous Next Go Back To duplex sensor To duplex sensor 7-14 Service Manual...
  • Page 539 MPF tray door assembly (T652) 40X1884 MPF tray door assembly (T654) 40X4313 Pick arm sensor cable assembly 40X4304 Pick arm assembly with spring, 250 sheet (T650) 40X4305 Pick arm assembly with spring, 500 sheet (T652, T654, and T656) 40X4306 Pick arm spring (T650) 40X4308...

  • Page 540: Assembly 8: Lvps, Fuser And Electrical Cables 1

    4062-XXX Assembly 8: LVPS, fuser and electrical cables 1 Previous Next Go Back 7-16 Service Manual...
  • Page 541 4062-XXX Assembly 8: LVPS, fuser and electrical cables 1 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X1870 100V type 1 fuser assembly 40X4418 110V type 1 fuser assembly Next 40X1871 220V type 1 fuser assembly 40X5853 100V type 2 fuser assembly Go Back...

  • Page 542: Assembly 9: Hvps, System Card, And Electrical Cables 2

    4062-XXX Assembly 9: HVPS, system card, and electrical cables 2 Previous Next Go Back 7-18 Service Manual...
  • Page 543 Envelope / input option tray cable assembly 40X5911 System card assembly (T654) 40X7036 System card assembly (T656) 40X4375 System card assembly (T650) 40X4474 System card assembly (T652) 40X4376 Output option interface cable assembly Warning: When replacing any of the following components: •...

  • Page 544: Assembly 10: 250 Sheet Option Tray Assembly

    4062-XXX Assembly 10: 250 Sheet option tray assembly Previous Next Go Back 7-20 Service Manual...
  • Page 545 4062-XXX Assembly 10: 250 Sheet option tray assembly Previous 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 Next 40X3448 250 Sheet bellcrank recoil spring 40X4308 Pick roll assembly (2) Go Back...

  • Page 546: Assembly 11: 550 Sheet Option Tray Assembly

    4062-XXX Assembly 11: 550 Sheet option tray assembly Previous Next Go Back 7-22 Service Manual...
  • Page 547 4062-XXX Assembly 11: 550 Sheet option tray assembly Previous 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 Next 40X4307 550 Sheet bellcrank recoil spring 40X4308 Pick roll assembly (2) Go Back...

  • Page 548: Assembly 12: Hcit Sheet Option Tray Assembly

    4062-XXX Assembly 12: HCIT Sheet option tray assembly Previous Next Go Back 7-24 Service Manual...
  • Page 549 4062-XXX Assembly 12: HCIT Sheet option tray assembly Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4579 Complete HCIT option tray assembly 40X4590 HCIT pick arm bracket assembly Next 40X4595 Pick arm sensor cable assembly 40X4591 HCIT bellcrank recoil spring Go Back 40X4308...

  • Page 550: Assembly 13: Sfp Stapler Assembly #1

    4062-XXX Assembly 13: SFP stapler assembly #1 Previous Next Go Back 7-26 Service Manual...
  • Page 551 4062-XXX Assembly 13: SFP stapler assembly # 1 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5547 SFP stapler assembly (comes completely assembled) Next Go Back 7-27 Parts catalog...

  • Page 552: Assembly 14: Sfp Stapler Assembly #2

    4062-XXX Assembly 14: SFP stapler assembly #2 Previous Next Go Back 7-28 Service Manual...
  • Page 553 4062-XXX Assembly 14: SFP stapler assembly #2 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4612 Handle cover 40X4613 Rear door assembly Next 40X5910 Stapler cover 40X4610 Right cover Go Back 40X5544 Sensor (bin full receive) 40X4617 Finisher bin spring 40X5545...

  • Page 554: Assembly 15: Sfp Stapler Assembly #3

    4062-XXX Assembly 15: SFP stapler assembly #3 Previous Next Go Back 7-30 Service Manual...
  • Page 555 4062-XXX Assembly 15: SFP stapler assembly #3 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4645 Media stack flap actuator 40X4646 Media stack flap Next 40X4369 Sensor (media stack) 40X4621 Left tamper motor assembly Go Back 40X4622 Right tamper motor assembly 40X4624...

  • Page 556: Assembly 16: Sfp Stapler Assembly #4

    4062-XXX Assembly 16: SFP stapler assembly #4 Previous Next Go Back 7-32 Service Manual...
  • Page 557 4062-XXX Assembly 16: SFP stapler assembly #4 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4641 Stapler assembly 40X5909 Sensor (media in stapler) Next Go Back 7-33 Parts catalog...

  • Page 558: Assembly 17: 5-Bin Mailbox #1

    4062-XXX Assembly 17: 5-bin mailbox #1 Previous Next Go Back 7-34 Service Manual...
  • Page 559 4062-XXX Assembly 17: 5-bin mailbox #1 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5550 Complete 5 bin mailbox unit assembly 40X5708 Top cover Next 40X5709 Rear door assembly 40X5712 Right outer cover Go Back 40X5713 Right inner cover 40X5756 Output bin LED bracket...

  • Page 560: Assembly 18: 5-Bin Mailbox #2

    4062-XXX Assembly 18: 5-bin mailbox #2 Previous Next Go Back 7-36 Service Manual...
  • Page 561 4062-XXX Assembly 18: 5-bin mailbox #2 Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5550 Complete 5 bin mailbox unit assembly 40X0028 Spring (top) Next 40X2036 Deflector gate (top) 40X4772 Static brush mylar assembly Go Back 40X2037 Deflector gate 40X2065...

  • Page 562: Assembly 19: High Capacity Stacker

    4062-XXX Assembly 19: High capacity stacker Previous Next Go Back 7-38 Service Manual...
  • Page 563 4062-XXX Assembly 19: High capacity stacker Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5730 Complete high capacity stacker assembly 40X5737 Rear door assembly Next 40X1988 Deflector gate 40X3264 Sensor (pass through) Go Back 40X5733 High capacity output controller card assembly 40X5734 Right frame 40X5735...

  • Page 564: Assembly 20: Output Expander

    4062-XXX Assembly 20: Output expander Previous Next Go Back 7-40 Service Manual...
  • Page 565 4062-XXX Assembly 20: Output expander Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5719 Complete output expander assembly 40X5722 Rear door assembly Next 40X1988 Deflector gate 40X3264 Sensor (pass through) Go Back 40X1991 Output expander media bin latch 40X5726 Right inner cover 40X5725...

  • Page 566: Assembly 21: Envelope Feeder And External Duplex

    4062-XXX Assembly 21: Envelope feeder and external duplex Previous Next Go Back 7-42 Service Manual...
  • Page 567 Assembly 21: Envelope feeder and external duplex Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5739 Envelope feeder (T650, T652, and T654 only - will not fit the T656) 40X5904 External duplex Next Go Back 7-43 Parts catalog...

  • Page 568: Assembly 22: Rfid Uhf Option Assembly

    4062-XXX Assembly 22: RFID UHF Option assembly Previous Next Go Back Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X1483 US RFID UHF option assembly including: A. RFID UHF option B. Firmware card C. User flash card D.

  • Page 569: Assembly 23: Miscellaneous

    Lexmark N4050e (1 port USB) wireless 802.11g (US/Americas) 40X1593 MarkNet N7000e Fash Ethernet 10/100BaseTX-USB 40X1594 MarkNet N7002e Fast Ethernet 10/100BaseTX - Parallel 40X1592 Lexmark MarkNet N7020e (4 port USB) ethernet 10base T/100Base TX/1000BaseT 40X4819 RS-232C serial interface card 7-45 Parts catalog...
  • Page 570 4062-XXX Assembly 23 (continued): Miscellaneous Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X4823 Parallel 1284-B interface card Next 40X1367 10-Foot parallel printer cable 40X2665 Fuser oil wiper (black housing) Go Back 40X2666 Fuser wax wiper (gray housing) 40X1368 2-Meter USB printer cable 7-46...

  • Page 571: Assembly 24: Power Cords

    4062-XXX Assembly 24: Power cords Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X0269 Power cord LV, USA & Canada, Latin America Next 40X0288 Power cord HV, Argentina 40X1766 Power cord HV, Bolivia & Peru Go Back 40X0273 Power cord HV, Chile, Uruguay 40X3141...

  • Page 572: Assembly 25: Universal Trays And Accessories

    4062-XXX Assembly 25: Universal trays and accessories Previous Asm- Part Units/ Units/ kit Description Index number mach or pkg 40X5857 Universal media drawer with tray, 200 sheet Next 40X5858 Universal media tray, 200 sheet 40X5859 Universal media drawer with tray, 400 sheet Go Back 40X5860 Universal media tray, 400 sheet...
  • Page 573 4062-XXX Index Previous Numerics diagnostic information Next confirm the installation status 5-bin mailbox Power-on Reset sequence 3-18 output sensor test diagnostics 2-14 error code table Go Back diagnostics menu 3-89 acronyms 3-30 accessing adjustments 3-31 available tests fuser solenoid 3-42 BASE SENSOR TEST gap adjustment DEVICE TESTS...
  • Page 574 4062-XXX 3-33 3-37 REGISTRATION DRAM Test Previous 3-34 3-93 Quick Test Duplex diagnostics mode duplex tests 3-14 3-40 accessing Duplex Feed 1 3-14 3-40 available tests Duplex Feed 2 3-19 3-39 BASE SENSOR TEST Left Margin Next 3-14 3-39 DUPLEX TESTS Motor Test 3-14 3-12...
  • Page 575 3-39 duplex 3-65 sensor (feed-out) 3-58 LES Applications 3-65 3-87 3-92 sensor (media level) 3-58 Lexmark Embedded Solution 3-65 3-87 3-91 sensor (media out) ii-xxi 4-75 lithium battery 3-65 3-87 3-91 switch (media size) lubrication specifications...
  • Page 576 4062-XXX 3-13 3-38 duplex Previous 3-33 simplex (front side) 3-88 unique tools upper front cover parts catalog Next 3-59 USB speed Go Back 3-21 3-46 warm up time 3-57 Wipe Disk 3-58 Wiper Message Service Manual...

  • Page 577: Part Number Index

    Lexmark MarkNet N7002e (1 port parallel) ethernet 10baseT/100BaseTX - - - - - - - - - - - - - - - - - - - - - 7-45 40X1594 Lexmark MarkNet N7002e (1 port parallel) ethernet 10base T/100Base TX - - - - - - - - - - - - - - - - - - - - 7-45 40X1766 Power cord HV, Bolivia &...
  • Page 578 Aligner assembly with ground strap and adj.
  • Page 579 Inner cover, right (T650, T652, and T654) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 580 Printhead with cable assembly (T650) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 581 Connection bezel assembly, rear (T650) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 582 Rear door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-39 40X5739 Envelope feeder (T650, T652, and T654 only - will not fit the T656dne) - - - - - - - - - - - - - - - - - - - - - - 7-43 40X5746...
  • Page 583 7-45 56P2744 Lexmark N4050e (1 port USB) wireless 802.11g (US/Americas) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45 56P4191...
  • Page 584 4062-XXX Previous Next Go Back I-12 Service Manual...
  • Page 585 Print defects guide Page 1 of 1 Print defects guide Match a set of repeating defects on a print job to the marks on one of the vertical lines. The line that best matches the defects on the print job indicates which particular part may be causing the defect. For example, the distance between these two marks represents a repeating defect that occurs every 28.3 mm (1.11 in.), which means the charge rollers may need to be replaced.

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