Dell Multifunction Laser Printer 5535dn Service Manual Download Page 576 | Manualshive

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6-2

Service Manual

Scheduled maintenance

Maintenance kit

The operator panel displays the message

80 Scheduled Maintenance

at each 300K page count interval. It is

necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain
the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part
numbers:

After replacing the kit, the maintenance count must be reset to zero to clear the “80 Scheduled Maintenance”

Maintaining the printer

Periodically, certain tasks are required to maintain optimum print quality.

Cleaning the exterior of the printer

1.

Make sure that the printer is turned off and unplugged from the wall outlet.

CAUTION:

SHOCK HAZARD: To avoid the risk of electric shock when cleaning the exterior of the

printer, unplug the power cord from the wall outlet and disconnect all cables to the printer before
proceeding.

2.

Remove paper from the standard exit bin.

3.

Dampen a clean, lint-free cloth with water.

Warning:

Do not use household cleaners or detergents, as they may damage the finish of the printer.

4.

Wipe only the outside of the printer, making sure to include the standard exit bin.

Warning:

Using a damp cloth to clean the interior may cause damage to your printer.

5.

Make sure the paper support and standard exit bin are dry before beginning a new print job.

Maintenance kits

Description

Part number

Maintenance

Interval

Printer maintenance kit (100V)

40X4723

300K

Printer maintenance kit (110V)

40X4724

300K

Printer maintenance kit (220V)

40X4765

300K

Printer maintenance kit (100V type 2 fuser)

40X4766

150K

Printer maintenance kit (110V type 2 fuser)

40X4767

150K

Printer maintenance kit (220V type 2 fuser)

40X4768

150K

ADF maintenance kit - includes:

• ADF feed/pick roll assembly
• ADF separator roll and guide

40X4769

120K

message. See

“Reset Maintenance Counter” on page 3-29

.

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Summary of Contents for Multifunction Laser Printer 5535dn

Page 1: ... SULO ...

Page 2: ... ...

Page 3: ...7 Sensor input service check 2 107 Sensor fuser output service check 2 107 Sensor narrow media service check 2 108 Sensor duplex input service check 2 108 Sensor duplex input service check external duplex only 2 109 Sensor pass through service check 2 109 Sensor duplex exit service check external duplex only 2 109 Sensor envelope feeder empty service check 2 110 Sensor ADF top door interlock servi...

Page 4: ...0 Image quality trouble 2 151 Printer Related Troubleshooting 2 151 Image Quality 2 152 Image quality symptoms 2 151 Faint print Low contrast 2 152 Blank print no print 2 154 Solid black 2 156 Vertical lines and bands process direction 2 157 Horizontal white stripes or bands side to side direction 2 158 Vertical stripes process direction 2 159 Horizontal stripes side to side direction 2 160 Partia...

Page 5: ...in duplex 3 17 Sensor Test duplex 3 17 Motor Test duplex 3 17 Duplex Feed 1 3 18 Duplex Feed 2 3 18 INPUT TRAY TESTS 3 19 Feed Tests input tray 3 19 Sensor Test input tray 3 19 OUTPUT BIN TESTS 3 20 Feed Tests output bins 3 20 Sensor Test standard output bin 3 20 BASE SENSOR TEST 3 20 DEVICE TESTS 3 21 Quick Disk Test 3 21 Disk Test Clean 3 21 PRINTER SETUP 3 22 Defaults 3 22 Printed Page Count 3 ...

Page 6: ...ormat Fax Storage 3 34 Fax Storage Location 3 34 ADF Edge Erase 3 34 FB Edge Erase 3 35 Scanner Manual Registration 3 35 Disable Scanner 3 36 Paper Prompts 3 36 Envelope Prompts 3 36 Action for Prompts 3 37 Jobs On Disk 3 38 Disk Encryption 3 38 Wipe Disk 3 39 Font Sharpening 3 39 Require Standby 3 39 LES Applications 3 40 Key Repeat Initial Delay 3 40 Key Repeat Rate 3 40 Wiper Message 3 40 Clear...

Page 7: ...3 57 Type 1 fuser unit assembly 3 57 Type 2 fuser unit assembly 3 57 Exit 3 58 Sensor standard bin full 3 58 Drive 3 58 Main drive motor assembly 3 58 Redrive motor assembly 3 59 Electrical components and controller 3 59 Switch printer front door interlock 3 59 Main cooling fan 3 60 Print cartridge cooling fan 3 60 Duplex cooling fan 3 60 LVPS card assembly 3 60 LVPS cooling fan 3 60 HVPS card ass...

Page 8: ... 72 Sensor ADF 1st scan 3 72 Sensor 2nd scan 3 72 Sensor ADF media exit 3 72 ADF feed motor assembly 3 72 ADF transport motor 3 72 ADF pick solenoid assembly 3 72 High Capacity Input Tray HCIT tray assembly 3 74 250 sheet 550 sheet tray assembly 3 75 Media size sensing 3 75 Media level sensing 3 76 Pick motor 3 76 Sensor A B 3 76 Sensor pass thru 3 76 Media transport path 3 78 Model X658 paper pat...

Page 9: ...rge roll assembly removal 4 6 Duplex assembly removal 4 7 Duplex cooling fan removal 4 8 Duplex drive motor assembly removal 4 9 Duplex input sensor assembly removal 4 10 Duplex guide assembly front removal 4 10 Media turn guide removal 4 12 Fuser access door assembly removal 4 12 Main cooling fan removal 4 14 Fuser drive release linkage removal 4 15 Fuser unit assembly removal 4 15 Fuser wiper co...

Page 10: ...separator torque limiter assembly removal 4 63 ADF cover front removal 4 64 ADF cover rear removal 4 65 ADF document tray assembly removal 4 65 ADF top door assembly removal 4 66 ADF controller card removal 4 67 ADF platen cushion removal 4 68 ADF lower door assembly removal 4 68 ADF duplex CCD scan glass assembly removal X654 X656 and X658 4 69 ADF duplex CCD assembly removal X654 X656 and X658 4...

Page 11: ...removal 4 124 Cover rear lower removal 4 125 Scanner support cover right rear removal model X658 4 127 Scanner support inner cover right removal model X658 4 128 Scanner support cover right removal model X658 4 129 Scanner controller card assembly removal model X658 4 129 Scanner controller card assembly removal models X651 X652 5535dn X654 and X656 4 132 Scanner cover rear removal 4 133 Scanner c...

Page 12: ...removal 4 186 Media tray catch spring removal 4 187 Tray roller catch assembly removal 4 188 550 sheet option tray assembly 4 190 550 sheet media tray assembly removal 4 191 550 sheet option drawer assembly removal 4 191 550 sheet pick arm bracket assembly removal 4 192 550 sheet bellcrank recoil spring removal 4 193 Anti tip latch assembly removal 4 194 550 sheet frame assembly removal 4 195 Uppe...

Page 13: ...ailbox empty removal 4 233 4 bin mailbox assembly standard output bin LED removal 4 234 4 bin mailbox assembly LED clear lens removal 4 236 4 bin mailbox assembly media bin full actuator removal 4 236 Offset stacker rear door assembly removal 4 237 Offset stacker right cover removal 4 237 Offset stacker left cover removal 4 238 Offset stacker top cover removal 4 238 Offset stacker handle cover rem...

Page 14: ...dex I 1 Assembly 16 250 Sheet option tray assembly X651 X652 5535dn X654 and X656 7 32 Assembly 18 HCIT Sheet option tray assembly X651 X652 5535dn X654 and X656 7 36 Assembly 19 MFP stapler assembly 7 38 Assembly 20 MFP stapler assembly 2 7 40 Assembly 21 MFP stapler assembly 3 7 42 Assembly 22 MFP stapler assembly 4 7 44 Assembly 23 MFP offset stacker assembly 1 7 46 Assembly 24 MFP Offset stack...

Page 15: ...Kundendienst Laserbestrahlung die Klasse I übersteigen würde Menschen keinesfalls erreicht Avis relatif à l utilisation de laser Pour les Etats Unis cette imprimante est certifiée conforme aux provisions DHHS 21 CFR alinéa J concernant les produits laser de Classe I 1 Pour les autres pays cette imprimante répond aux normes IEC 60825 1 relatives aux produits laser de Classe I Les produits laser de ...

Page 16: ...s operando numa faixa de comprimento de onda entre 770 e 795 nanómetros O sistema e a impressora laser foram concebidos de forma a nunca existir qualquer possiblidade de acesso humano a radiação laser superior a um nível de Classe I durante a operação normal a manutenção feita pelo utilizador ou condições de assistência prescritas Laserinformatie De printer voldoet aan de eisen die gesteld worden ...

Page 17: ...asersäteilylle Älä katso säteeseen VARNING Osynlig laserstrålning när denna del är öppnad och spärren är urkopplad Betrakta ej strålen Laser notis Denna skrivare är i USA certifierad att motsvara kraven i DHHS 21 CFR underparagraf J för laserprodukter av Klass I 1 I andra länder uppfyller skrivaren kraven för laserprodukter av Klass I enligt kraven i IEC 60825 1 Laserprodukter i Klass I anses ej h...

Page 18: ...ser de classe I no es consideren perillosos Aquesta impressora conté un làser de classe IIIb 3b d arseniür de gal li nominalment de 5 mil liwats i funciona a la regió de longitud d ona de 770 795 nanòmetres El sistema làser i la impressora han sigut concebuts de manera que mai hi hagi exposició a la radiació làser per sobre d un nivell de classe I durant una operació normal durant les tasques de m...

Page 19: ...Notices and safety information xix ...

Page 20: ...xx Service Manual ...

Page 21: ...n de ce produit pouvant présenter certains risques électriques le personnel d entretien qualifié devra prendre toutes les précautions nécessaires ATTENTION Ce symbole indique la présence d une tension dangereuse dans la partie du produit sur laquelle vous travaillez Débranchez le produit avant de commencer ou faites preuve de vigilance si l exécution de la tâche exige que le produit reste sous ten...

Page 22: ...ste producto está dirigida exclusivamente al personal cualificado de mantenimiento Existe mayor riesgo de descarga eléctrica y de daños personales durante el desmontaje y la reparación de la máquina El personal cualificado debe ser consciente de este peligro y tomar las precauciones necesarias PRECAUCIÓN este símbolo indica que el voltaje de la parte del equipo con la que está trabajando es peligr...

Page 23: ...nt a professionals i no està destinada a ningú que no ho sigui El risc de xoc elèctric i de danys personals pot augmentar durant el procés de desmuntatge i de servei d aquest producte El personal professional ha d estar ne assabentat i prendre les mesures convenients PRECAUCIÓ aquest símbol indica que el voltatge de la part de l equip amb la qual esteu treballant és perillós Abans de començar dese...

Page 24: ...locations and test points on the printer 6 Preventive maintenance contains the lubrication specifications and recommendations to prevent problems 7 Parts catalog contains illustrations and part numbers for individual FRUs Appendix A contains service tips and information Appendix B contains representative print samples Conventions Note A note provides additional information Warning A warning identi...

Page 25: ...tenance approach and fax functions designed to attach to most computer networks The operator panel is touch sensitive and x x x x x 7462 4A6 X658de x x x x 7462 4A2 X658de x x x x x 7462 436 X658de x x x x 7462 432 X658de x x x x x 7462 2A6 X656dte x x x x 7462 2A5 X656dte x x x x 7462 2A2 X654de x x x 7462 2A1 X654de x x x x x 7462 236 X656dte x x x x 7462 235 X656dte x x x x 7462 232 X654de x x ...

Page 26: ...eder ADF 2 Printer control panel 3 Standard exit bin 4 Multipurpose feeder 5 550 sheet tray Tray 1 6 550 sheet tray Tray 2 7 Optional output bin 1 3 4 5 6 2 2 7 CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations More information is available on our Dell...

Page 27: ...SP MarkNetTM N8150802 11 b g n Wireless ISP MarkNet N8130 10 100 Fiber ISP MarkNet N8120 10 100 1000 Ethernet ISP MarkNet N8110 V 34 Fax Card Media handling options 250 and 550 sheet paper trays of A4 letter A5 B5 Executive folio statement and legal size 250 sheet universally adjustable tray 250 and 550 sheet paper drawers 2000 sheet high capacity feeder Envelope feeder Duplex option 250 sheet Dup...

Page 28: ...x A61 2 105 x 148 mm 4 1 x 5 8 in x J15 B5 182 x 257 mm 7 2 x 10 1 in x x x Letter 216 x 279 mm 8 5 x 11 in x x x x Legal 216 x 356 mm 8 5 x14 in x x x x Executive 184 x 267 mm 7 3 x 10 5 in x x x Oficio1 216 x340 mm 8 5 x 13 4 in x x x Folio1 216 x 330 mm 8 5 x 13 in x x x Statement1 140 x 216 mm 5 5 x8 5 in x x Universal3 4 138 x 210 mm 5 5 x8 3 in up to 216 x 356 mm 8 5 x 14 in x x 70 x 127 mm ...

Page 29: ...ing formats the page for 216 x 356 mm 8 5 x 14 in unless the size is specified by the software application 4 To support duplexing the Universal width must be between 148 mm 5 8 in and 216 mm 8 5 in Universal length must be between 182 mm 7 2 in and 356 mm 14 in Paper type 250 or 550 sheet trays standard or optional Optional 2000 sheet tray Multipurpose feeder Duplex unit Paper Plain Bond Colored C...

Page 30: ...2 Paper Plain Bond Colored Custom Letterhead Light Heavy Preprinted Rough Cotton Recycled x x x x Card stock x x Envelopes Labels3 x x Transparencies x x 1 Supports 60 90 g m2 16 24 lb paper weights 2 Maximum of 50 sheets of 75 g m2 20 lb paper per stapled packet Results may vary with heavier paper 3 Printing labels require a special label fuser cleaner which prevents duplexing The label fuser cle...

Page 31: ...ewdrivers various sizes Phillips screwdrivers various sizes 7 32 inch open end wrench 7 0 mm nut driver 5 5 mm wrench Needlenose pliers Diagonal side cutters Spring hook Analog or digital multimeter Flash light optional General information 1 7 ...

Page 32: ...uid Crystal Display LED Light Emitting Diode LVPS Low Voltage Power Supply MDC Motor Driver Control MFP Multifunction Printer MPF Multipurpose Feeder NVRAM Nonvolatile Random Access Memory OPT Optical Sensor PC Photoconductor PIN Personal Identification Number PJL Printer Job Language POR Power On Reset POST Power On Self Test PP Parts Packet PWM Pulse Width Modulation RIP Raster Imaging Processor...

Page 33: ...next level support for assistance CAUTION electronic board or assembly CAUTION If the printer is kept on never touch the conductive parts if not specifically required The power switch and inlet of the low voltage power supply card LVPS card assembly is live even while the power supply is cut off Never touch the live parts CAUTION Be careful to avoid burns by safely handling hot parts CAUTION The p...

Page 34: ...as is generated The printer is not installed in direct sun The printer is installed on a level and stable surface Media meets specifications and is installed properly Customer maintenance parts have been replaced at the specified intervals Check all attached options for proper attachment and electrical connection Refer to the User s Guide for proper installation Power on Reset sequence The followi...

Page 35: ...r assembly if 32 XX Cartridge part number X unsupported by device Error 32 displays when the top cover is closed and an unsupported print cartridge is detected It may take the printer 10 20 seconds to determine if the print cartridge is supported Install the proper print cartridge 34 Short Paper The printer determines the paper length is too short to print the formatted data This occurs when the p...

Page 36: ...quired after this message is received the customer should install additional memory or set each link buffer to Auto Once all link buffers are returned to Auto you should exit the menu to activate the link buffer changes Once the printer returns to the Ready state you can enable Resource Save and go back and modify the link buffers again Note the reduction of available memory to the link buffers wh...

Page 37: ...g job and there is insufficient memory available to continue processing the job The following actions may be taken Press to clear the message Perform the defragment operation Perform the defragment operation Delete fonts macros and other data in RAM Install additional memory Press to display Busy Waiting The following functions may be available Cancel Job Reset Printer Reset Active Bin 39 Complex ...

Page 38: ...cts a defective flash This error may occur at power on or during flash format and write operations Press to clear the message The flash is marked as bad and normal operation continues Flash operations are not allowed until the problem is resolved 52 Flash Full This message displays when the printer detects an unformatted flash at power on Press to clear the message The flash is marked as bad and n...

Page 39: ...across an optional parallel port but the port has been disabled Once this message displays reporting of further errors is suppressed until the menus are entered or the printer is reset Go to network service check 56B Serial Port x Disabled This error displays when data is sent to the printer across an serial port but the port has been disabled Once this message displays reporting of further errors...

Page 40: ...inter and turn it on 58C Too Many Flash Options This error code displays when too many user flash memory options or too many optional firmware cards have been installed User can power off and remove extra flash options 1 Turn off and unplug the printer 2 Remove the excess flash memory 3 Plug in the printer and turn it on 58D Too Many Trays Attached This error code displays when too many input tray...

Page 41: ... Incompatible Tray x An incompatible tray is installed For Tray x x 2 3 4 or 5 Remove the incompatible tray and press to clear the message Note If the user installed the incompatible device to satisfy a Check Device Connections reattach message the user should reinstall an associated compatible option or hot unplug the option 1 Turn off and unplug the printer 2 Remove the incompatible trays 3 Plug...

Page 42: ...ow occurs and the cartridge low alarm is activated If cartridge alarm is not activated this is not an intervention condition Replace the print cartridge 88C Cartridge Nearly Low This IR is displayed when cartridge low occurs and the cartridge low alarm is activated If cartridge alarm is not activated this is not an intervention condition Replace the print cartridge 88C Replace Cartridge This IR is...

Page 43: ...auses engine to assume 500 paper path on 250 model 1 Fan the media and ensure it is properly installed 2 Go to sensor input early jam service check 200 06 Sensor input early jam The sensor input rebounded once the trailing edge of the media passed Go to sensor input service check 200 07 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input l...

Page 44: ...tions on 4 Replace the printhead if problem remains Go to 200 12 Laser power signal error The printhead laser power signal has failed 1 Remove all media present in media path 2 Check all connections on the printhead 3 Check all connections on the system card assembly Replace the printhead if problem remains Go to 4 Replace the system card if problem remains Go to jam input during the warm up seque...

Page 45: ...ut lingering jam service check 200 19 Sensor input lingering jam The media reached the sensor input but did not clear it within the specified time Go to sensor input lingering jam service check 200 27 Sensor input lingering jam The media reached the sensor input but did not clear it within the specified time Go to sensor input lingering jam service check lingering jam input but did not clear it wi...

Page 46: ... specified time Go to sensor input lingering jam service check 200 38 Sensor input The media reached the sensor the specified time Go to sensor input lingering 200 39 Sensor input lingering jam The media reached the sensor input but did not clear it within the specified time Go to sensor input lingering jam service check 200 47 Sensor input The media reached the sensor the specified time Go to sen...

Page 47: ...problem remains a type 2 fuser can be installed 201 04 Sensor narrow media late jam The expected wide media is late reaching the sensor narrow media within the specified time Go to sensor narrow media late jam service check Error code or message Error contents Description Action Possible repair actions Source Tray 4 See Sensor input lingering page 2 129 200 49 Sensor input The media reached the se...

Page 48: ... the specified time Go to sensor narrow media late jam service check 201 30 Operator panel door assembly interlock switch failure Type 2 fuser The printer detected that the operator panel door interlock switch did not cycle prior to printer restart 1 Remove all media present in media path 2 Ensure that the operator panel door assembly is fully open then fully closed 3 Check operator panel door ass...

Page 49: ... fuser output late jam service check If problem remains a type 2 fuser can be installed 201 54 Sensor narrow media late jam Fuser page count has exceeded life The media is late reaching the sensor narrow media within the specified time Go to sensor narrow media late jam service check 201 55 Operator panel door assembly interlock switch open failure Type 1 fuser Fuser page count has exceeded life T...

Page 50: ...dia is late reaching the sensor fuser output within the specified time Go to sensor fuser output late jam service check 201 79 Sensor narrow media late jam Fuser page count has exceeded life The media is late reaching the sensor narrow media within the specified time Go to sensor narrow media late jam service check 201 80 Operator panel door assembly interlock switch open failure Type 2 fuser Fuse...

Page 51: ...fuser output lingering jam service check 202 03 Sensor narrow media static jam Media remains on the sensor narrow media during the warm up sequence Go to sensor narrow media static jam service check 202 04 Sensor fuser output bounce The sensor fuser output rebounded once the trailing edge of the media passed Go to sensor fuser output service check 202 06 Sensor fuser output static jam Type 1 fuser...

Page 52: ...ype 1 fuser Media reached the sensor fuser output but did not clear it in the specified time and Media did reach the sensor narrow media Go to sensor fuser output lingering jam service check 202 13 Sensor fuser output static jam and Sensor narrow media static jam Type 1 fuser Media remains on the sensor fuser output and the sensor 1 Go to sensor fuser output static jam service check 2 Go to sensor...

Page 53: ... fuser output rebounded once the trailing edge of the media passed Go to sensor fuser output service check 202 30 Never sent the divert command to the stacker Type 2 fuser 202 31 Sensor fuser output static jam Media remains on the sensor fuser output during the warm up sequence Go to sensor fuser output static jam service check 202 32 Sensor fuser output lingering jam Media reached the sensor fuse...

Page 54: ...r Media remains on the sensor fuser output and the sensor 1 Go to sensor fuser output static jam service check 2 Go to sensor narrow media static jam service 202 50 Paper jam around fuser exit or redrive area Type 1 fuser Fuser page count has exceeded life Page may be jammed in fuser exit or redrive area 1 Remove all media present in media path 2 Check media for proper installation 3 Check for obs...

Page 55: ... jam Fuser page count has exceeded life Media reached the sensor fuser output but did not clear it in the specified time Go to sensor fuser output lingering jam service check 202 59 Sensor fuser output lingering jam Fuser page count has exceeded life Media reached the sensor fuser output but did not clear it in the specified time Go to sensor fuser output lingering jam service check 202 60 Sensor ...

Page 56: ...bstructions in media path 4 Go to sensor fuser output service check See 5 Go to sensor narrow media service check See 202 76 Sensor fuser output lingering jam Type 2 fuser Fuser page count has exceeded life Media reached the sensor fuser output but did not clear it in the specified time Media did not reach the sensor narrow media Go to sensor fuser output lingering jam service check 202 77 Sensor ...

Page 57: ... jam service check 202 85 Sensor fuser output lingering jam Destination is output option Type 2 fuser Fuser page count has exceeded life Media reached the sensor fuser output but did not clear it in the specified time Media did not reach the sensor narrow media Go to sensor fuser output lingering jam service check 202 86 Sensor fuser output lingering jam Destination is standard bin Type 2 fuser Fu...

Page 58: ...path 4 Go to sensor fuser output service check See 5 Go to sensor narrow media service check See 203 01 Internal duplex drive motor control failure Internal duplex The internal duplex drive motor motor does not reach the proper operating speed at the specified time 1 Remove all media present in media path 2 Check all connections on the duplex media entrance drive motor assembly 3 Check all connect...

Page 59: ...rive motor assembly if problem 203 18 Redrive motor assembly underspeed error The redrive motor assembly does not rotate at the specified speed 1 Remove all media present in media path 2 Ensure that upper redive assembly is properly installed 3 Check all connections on the redrive motor assembly 4 Check all connections on the system card assembly 5 Replace the redrive motor assembly if problem 203...

Page 60: ...time Go to sensor duplex input lingering jam service check 230 06 Sensor input late jam from duplex Media is late reaching the sensor input within the specified time during the second side printing using the internal duplex Go to sensor input late jam service check 230 07 Sensor input late jam from duplex Media is late reaching the sensor input within the specified time during the second side prin...

Page 61: ...duplex input static jam service check 230 14 Paper jam around internal duplex Source Internal duplex Page may be jammed in internal duplex area 1 Remove all media present in media path 2 Check for obstructions in media path 3 Go to sensor fuser output service check See 4 Go to sensor duplex input service check See 230 18 Internal duplex drive motor assembly underspeed error Source Internal duplex ...

Page 62: ... it in the specified time Go to sensor duplex input lingering jam service check 233 00 Sensor duplex double feed late jam Source External duplex Media is late reaching the sensor duplex double feed within the specified time 1 Remove all media present in media path 2 Check for obstructions in media path 3 Ensure the external duplex assembly is properly installed 4 Ensure the rear door of the extern...

Page 63: ...sure the external duplex assembly is properly installed 5 Replace the external duplex assembly if problem remains 236 00 Sensor duplex exit lingering jam Source External duplex Media reached the sensor duplex exit within the specified time but did not clear it within the specified time 1 Remove all media present in media path 2 Check media for proper installation 3 Check for obstructions in media ...

Page 64: ...Replace the external duplex assembly if problem remains 238 01 Sensor duplex input static jam Media remains on the sensor duplex input during the warm up sequence Go to sensor duplex input static jam service check 238 02 Sensor duplex exit static jam Source External duplex Media remains on the sensor duplex exit during the warm up sequence 1 Remove all media present in media path 2 Go to sensor du...

Page 65: ...ssembly if problem remains 238 07 Sensor duplex input static jam Sensor double feed static jam Sensor duplex exit Source External duplex Media remains on the sensor duplex input sensor double feed and the sensor duplex exit during the warm up sequence Go to sensor duplex input static jam service check 239 00 Mechanical feed error or timing error Source External duplex Mechanical feed error or timi...

Page 66: ...or proper installation 3 Check for obstructions in media path 4 Ensure the external duplex assembly is properly installed 5 Ensure the rear door of the external duplex is fully closed 6 Check all connections on the external duplex assembly 7 Replace the external duplex assembly if problem remains 239 03 Device controls response error Source External duplex Mechanical feed error or timing error 1 R...

Page 67: ...for proper installation 3 Check for obstructions in media path 4 Ensure the external duplex assembly is properly installed 5 Ensure the rear door of the external duplex is fully closed 6 Check all connections on the external duplex assembly 7 Replace the external duplex assembly if problem remains 239 06 Failed the last page of a staple job Source External duplex Mechanical feed error or timing er...

Page 68: ... Check for obstructions in media path 4 Ensure the external duplex assembly is properly installed 5 Ensure the rear door of the external duplex is fully closed 6 Check all connections on the external duplex assembly 7 Replace the external duplex assembly if problem remains 239 11 Sensor input late jam from duplex Media is late reaching the sensor input within the specified time during the second s...

Page 69: ... has failed or caused high mechanical load due to paper jam or bind 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check clean or replace the pick rolls for wear and excess contamination Go 4 Check all connections on the pick arm assembly 5 Check all connections on the system card assembly 6 Replace the pick arm assembly if problem 7 Replace system card assembly i...

Page 70: ...41 14 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input late jam service check 241 15 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input late jam service check 241 16 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input l...

Page 71: ...media present in media path 2 Check media for proper installation 3 Check for obstructions in media path 242 02 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 242 03 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass th...

Page 72: ...gh late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 242 17 Media tray pulled jam Source Tray 2 A media tray above the source tray was pulled during the printing process 1 Remove all media present in media path 2 Close all media trays 242 18 Pick retry timeout Source Tray 2 The engine timed out waiting for the tra...

Page 73: ...the warm up sequence Go to sensor pass through static jam service check 242 37 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 242 39 Media tray pulled jam A media tray above the source tray was pulled during the printing process 1 Remove all media present in media path 2 Close all media tray...

Page 74: ...assembly for binding or damage 3 Replace the HCIT tray lift motor assembly if problem remains 242 52 HCIT tray lift motor overrun failure Source Tray 2 The HCIT tray lift motor continues to detect pulses after the motor has turned off 1 Ensure the HCIT media tray assembly is properly inserted into the machine 2 Check the HCIT tray lift motor assembly for binding or damage 3 Replace the HCIT tray l...

Page 75: ...l connections on the system card assembly 5 Replace the pick arm assembly if problem 6 Replace system card assembly if problem 242 67 Pick motor overspeed failure Source Media tray 2 The pick motor does not rotate at the specified speed 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the syst...

Page 76: ... path 2 Check media for proper installation 3 Check for obstructions in media path 243 02 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 243 03 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service...

Page 77: ...tray was pulled during the printing process 1 Remove all media present in media path 2 Close all media trays 243 18 Pick retry timeout Source Tray 3 The engine timed out waiting for the tray 3 to report ready before the first pick attempt Turn the machine off on 243 19 Pick retry timeout Source Tray 3 The engine timed out waiting for the tray 3 to report ready before a pick retry attempt Turn the ...

Page 78: ...rce Tray 3 The HCIT tray lift motor has stalled or has become obstructed 1 Ensure the HCIT media tray assembly is properly inserted into the machine 2 Check the HCIT tray lift motor assembly for binding or damage 3 Replace the HCIT tray lift drive motor assembly if problem remains 243 50 HCIT tray lift motor underspeed failure Source Tray 3 The HCIT tray lift motor does not rotate at the specified...

Page 79: ...onnections on the system card assembly 6 Replace the pick arm assembly if problem 7 Replace system card assembly if problem 243 66 Pick motor underspeed failure Source Media tray 3 The pick motor does not rotate at the specified speed 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the system...

Page 80: ...ce the pick arm assembly if problem 6 Replace system card assembly if problem 243 69 Pick motor control failure Source Media tray 3 The pick motor does not reach the proper operating speed at the specified time 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the system card assembly 5 Replace...

Page 81: ...but did not clear it within the specified time Go to sensor pass through lingering jam service check 244 10 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 244 13 Sensor pass through static jam Media remains on the sensor input during the warm up sequence Go to sensor pass through static jam ...

Page 82: ...the media out actuator if problem 244 36 Sensor pass through static jam Media remains on the sensor input during the warm up sequence Go to sensor pass through static jam service check 244 37 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 244 39 Media tray pulled jam Source Tray 4 A media tr...

Page 83: ...sembly for binding or damage 3 Replace the HCIT tray lift drive motor assembly if problem remains 244 52 HCIT tray lift motor overrun failure Source Tray 4 The HCIT tray lift motor continues to detect pulses after the motor has turned off 1 Ensure the HCIT media tray assembly is properly inserted into the machine 2 Check the HCIT tray lift motor assembly for binding or damage 3 Replace the HCIT tr...

Page 84: ...nnections on the system card assembly 5 Replace the pick arm assembly if problem 6 Replace system card assembly if problem 244 67 Pick motor overspeed failure Source Media tray 4 The pick motor does not rotate at the specified speed 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the system c...

Page 85: ...edia path 2 Check media for proper installation 3 Check for obstructions in media path 245 02 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam service check 245 03 Sensor pass through late jam The media is late reaching the sensor pass through within the specified time Go to sensor pass through late jam ser...

Page 86: ... was pulled during the printing process 1 Remove all media present in media path 2 Close all media trays 245 18 Pick retry timeout Source Tray 5 The engine timed out waiting for the tray 5 to report ready before the first pick attempt Turn the machine off on 245 19 Pick retry timeout Source Tray 5 The engine timed out waiting for the tray 5 to report ready before a pick retry attempt Turn the mach...

Page 87: ... Source Tray 5 The HCIT tray lift motor has stalled or has become obstructed 1 Ensure the HCIT media tray assembly is properly inserted into the machine 2 Check the HCIT tray lift motor assembly for binding or damage 3 Replace the HCIT tray lift drive motor assembly if problem remains 245 50 HCIT tray lift motor underspeed failure Source Tray 5 The HCIT tray lift motor does not rotate at the speci...

Page 88: ...ctions on the system card assembly 6 Replace the pick arm assembly if problem 7 Replace system card assembly if problem 245 66 Pick motor underspeed failure Source Media tray 5 The pick motor does not rotate at the specified speed 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the system car...

Page 89: ... problem 245 69 Pick motor control failure Source Media tray 5 The pick motor does not reach the proper operating speed at the specified time 1 Remove all media present in media path 2 Ensure media tray is not overfilled 3 Check all connections on the pick arm assembly 4 Check all connections on the system card assembly 5 Replace the pick arm assembly if problem 6 Replace system card assembly if p...

Page 90: ... Go to sensor input late jam service check 250 11 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input late jam service check 260 00 Envelope feeder area jam The media is jammed in the envelope feeder area 1 Remove the envelope feeder 2 Remove all media present in media path 3 Check media for proper installation 4 Check for obstructions in ...

Page 91: ...ia for proper installation 4 Check for obstructions in media path 5 Ensure the envelope feeder assembly is properly installed 6 Check all connections on the envelope feeder assembly 7 Replace the envelope feeder assembly if problem remains 260 05 Sensor envelope feeder pass through lingering jam Source Envelope feeder The media reached the sensor envelope feeder pass through but did not clear it i...

Page 92: ...or input within the specified time Go to sensor input late jam service check 260 12 Sensor input late jam The media is late reaching the sensor input within the specified time Go to sensor input late jam service check 260 13 sensor envelope feeder pass through static jam Media remains on the sensor envelope feeder pass through during the warm up sequence 1 Remove the envelope feeder 2 Remove all m...

Page 93: ...o Mailbox Error code or message Error contents Description Action Possible repair actions Source Envelope See Sensor input late jam page 2 127 Source Envelope See Sensor input late jam page 2 127 feeder service check on feeder service check on The media reached the sensor See Sensor output pass output pass through but did through lingering jam not clear it in the specified time service check on pa...

Page 94: ...tents Description Action Possible repair actions Media remains on the sensor See Sensor output pass output pass through during through static jam service the warm up sequence check on page 2 146 mailbox empty during the static jam service check on Media remains on the sensor See Sensor mailbox empty warm up sequence page 2 148 The media reached the sensor See Sensor output pass output pass through...

Page 95: ... the machine off on 2 Replace the output option if problem remains Error code or message Error contents Description Action Possible repair actions Go to MFP stapler assembly tamper drive motor assembly removal on page 4 210 Go to MFP stapler assembly sensor tamper HP left and right removal on page 4 217 mailbox empty but did not lingering jam service check The media reached the sensor See Sensor m...

Page 96: ...her The output option transport motor encoder is not detected upon startup 1 Check all connections on the output option controller card 2 Replace the output option if problem remains 28x 32 x bin number Transport motor encoder not detected Applies to StapleSmart finisher The transport motor encoder detection is lost during normal operation 1 Check all connections on the output option controller ca...

Page 97: ...s failed 1 Check all the connections on the controller card and the stapler assembly 2 Remove the staple cartridge and remove all jammed staples If the cartridge is jammed and can not be removed go to step 3 3 Remove the stapler assembly 4 Manually rotate the drive gears and reset the stapler Remove all jammed staples then reinstall the stapler assembly 5 If problem remains replace the stapler ass...

Page 98: ...art finisher The sensor self priming within the stapler assembly does not detect a ready staple in the specified time during mechanical reset 1 Check all the connections on the controller card and the stapler assembly 2 Remove the staple cartridge and remove all jammed staples If the cartridge is jammed and can not be removed go to step 3 3 Remove the stapler assembly 4 Manually rotate the drive g...

Page 99: ...StapleSmart finisher The sensor left tamper HP does not detect that the tamper has reached home position 1 Check all the connections on the output option controller card 2 Check the tamper drive belt for damage and replace if needed 3 Replace the left tamper motor assembly 4 Replace the sensor tamper HP 4 Replace the output option if problem remains Error code or message Error contents Description...

Page 100: ...eplace the sensor tamper HP 4 Replace the output option if problem remains 28x 44 x bin number Eject home position jam Applies to StapleSmart finisher The sensor eject HP does not detect that the eject mechanism is operating 1 Check all the connections on the output option controller card 2 Replace the output option if problem remains 28x 45 x bin number Eject home position jam Applies to StapleSm...

Page 101: ...e sensor deflector gate HP does not detect transition of the deflector gate to the output option 1 Check all the connections on the output option controller card 2 Check the sensor deflector HP for damage and replace if needed 3 Replace the output option if problem remains 28x 49 x bin number Deflector gate transition to standard bin not detected Applies to StapleSmart finisher The sensor deflecto...

Page 102: ...or assembly 4 Replace the sensor tamper HP 4 Replace the output option if problem remains 28x 52 x bin number Paddle control motor timer error Applies to StapleSmart finisher A software failure has occurred with the output option 1 Turn the machine off on 2 Replace the output option if problem remains 28x 53 x bin number Eject motor encoder not detected Applies to StapleSmart finisher The eject mo...

Page 103: ...m Applies to StapleSmart finisher The sensor self priming within the stapler unit assembly does not detect a ready staple in the specified time after the staple job was sent 1 Check all the connections on the controller card and the stapler assembly 2 Remove the staple cartridge and remove all jammed staples If the cartridge is jammed and can not be removed go to step 3 3 Remove the stapler assemb...

Page 104: ...lamp motor control timer error during tray holder initial Applies to StapleSmart finisher A software failure has occurred with the output option 1 Turn the machine off on 2 Replace the output option if problem remains 28x 65 x bin number Bin clamp home position jam Applies to StapleSmart finisher The bin clamp home position is not detected by the sensor bin clamp HP 1 Turn the machine off on 2 Rep...

Page 105: ...he sensor self priming within the stapler assembly does not detect a ready staple in the specified time after the staple job was sent Staples not empty 1 Check all the connections on the controller card and the stapler assembly 2 Remove the staple cartridge and remove all jammed staples If the cartridge is jammed and can not be removed go to step 3 3 Remove the stapler assembly 4 Manually rotate t...

Page 106: ...if problem remains 281 72 x bin number Sensor media in stapler static jam Applies to StapleSmart finisher Media remains on the sensor media in stapler during the warm up sequence 1 Inspect the sensor media in stapler for proper installation and reinstall if needed 2 Replace the sensor media in stapler Error code or message Error contents Description Action Possible repair actions Go to MFP stapler...

Page 107: ...nd The media does not reach the See Go to Sensor ADF 2nd scan late jam sensor ADF 2nd scan within scan late jam service check the specified time on page 2 149 291 02 Sensor ADF media The media does not reach the See Sensor ADF media exit late jam sensor ADF media exit within exit late jam service check the specified time on page 2 123 292 00 ADF top door open The ADF top door assembly See ADF top ...

Page 108: ... 1 POR the machine and print a simple test page to determine if the problem is system software related or if the customer is sending a corrupted print job 2 Check all connections on the system card assembly 3 Replace the system card assembly if problem 901xx System software error Code detected unusual event or timing 1 POR the machine and print a simple test page to determine if the problem is fir...

Page 109: ...ed unusual event or timing 1 POR the machine and print a simple test page to determine if the problem is system software related or if the customer is sending a corrupted print job 2 Check all connections on the system card assembly 3 Replace the system card assembly if problem 905 xx Interface violation by paperport device Code detected unusual event or timing 1 POR the machine and print a simple...

Page 110: ...m assembly 2 Check all the connections on the system card assembly 3 Replace the pick arm assembly if problem remains 912 00 Pick arm motor underspeed failure The pick arm motor does not rotate at the specified speed 1 Check all the connections on the pick arm assembly 2 Check all the connections on the system card assembly 3 Replace the pick arm assembly if problem remains 913 00 Pick arm motor o...

Page 111: ...d assembly 3 Replace the duplex drive motor assembly if problem remains 915 01 Redrive motor over speed failure The redrive motor does not rotate at the specified speed 1 Check all the connections on the duplex drive motor assembly 2 Check all the connections on the system card assembly 3 Replace the duplex drive motor assembly if problem remains 916 00 Internal duplex drive motor encoder not dete...

Page 112: ...ure the proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem 920 02 Fuser warm up failure Fuser type 1 The fuser hot roll fell to far below desired temperature while in standby control 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Replace the fuser unit asse...

Page 113: ...ge setting is being used on the switchable LVPS assembly 5 Replace the fuser unit assembly if problem 6 Replace the LVPS card assembly if problem 920 07 Fuser warm up failure Fuser type 1 The fuser hot roll temperature is not maintained properly while the media in the fuser nip 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is i...

Page 114: ... proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem 920 28 Fuser warm up failure Fuser type 2 The fuser hot roll is too cool while checking for slope change in standby 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem...

Page 115: ...der temperature Fuser type 1 Fuser page count has exceeded life Fuser does not maintain proper operating temperature within Replace the fuser unit assembly if problem remains 920 51 Fuser warm up failure Fuser type 1 Fuser page count has exceeded life The fuser hot roll took too long to heat up after transitioning to Replace the fuser unit assembly if problem remains 920 52 Fuser warm up failure F...

Page 116: ...ature Replace the fuser unit assembly if problem remains 920 78 Fuser warm up failure Fuser type 2 Fuser page count has exceeded life The fuser hot roll is too cool while checking for slope Replace the fuser unit assembly if problem remains 920 79 Fuser warm up failure Fuser type 2 Fuser page count has exceeded life The fuser hot roll is too cool when heating to desired Replace the fuser unit asse...

Page 117: ...nections on the fuser and LVPS card assembly 4 Replace the fuser unit assembly if problem 5 Replace the LVPS card assembly if problem 922 03 Fuser warm up failure Fuser type 1 The fuser hot roll does reach the final lamp detection parameter but not in the specified time 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed...

Page 118: ...ost this should really be a software error Turn the machine off on 922 06 Fuser warm up failure Fuser type 1 The fuser hot roll did not reach operating temperature within new enhanced control 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Check all connections on the fuser and LVPS card assembly 4 R...

Page 119: ...ser is installed in the machine 3 Replace the fuser unit assembly if problem 922 27 Fuser warm up failure Fuser type 2 The fuser hot roll does not reach the beginning lamp detection parameter in the specified time 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Check all connections on the fuser and ...

Page 120: ...e 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Check all connections on the fuser and LVPS card assembly 4 Replace the fuser unit assembly if problem 5 Replace the LVPS card assembly if problem 922 30 After hot roll lamp detection did not roll over to steady state control in time Fuser type 2 The ...

Page 121: ...em 922 50 Fuser warm up failure Fuser type 1 Fuser page count has exceeded life The fuser hot roll failed to reach target temperature Replace the fuser unit assembly if problem remains 922 52 Fuser warm up failure Fuser type 1 Fuser page count has exceeded life The fuser hot roll does not reach the beginning lamp Replace the fuser unit assembly if problem remains 922 53 Fuser warm up failure Fuser...

Page 122: ...ins 922 79 Fuser warm up failure Fuser type 2 Fuser page count has exceeded life The fuser hot roll has timed out and not reached final lamp Replace the fuser unit assembly if problem remains 922 81 Fuser warm up failure Fuser type 2 Fuser page count has exceeded life The fuser hot roll did not reach operating temperature within Replace the fuser unit assembly if problem remains 922 82 Fuser warm ...

Page 123: ...the machine 3 Replace the fuser unit assembly if problem 923 26 Fuser over temperature failure Fuser type 2 The fuser hot roll has exceeded the proper operating temperature 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem 923 50 Fuser over temperature failure...

Page 124: ...r thermistor might be faulty Replace the fuser unit assembly if problem remains 924 51 Open fuser thermistor check failure Fuser type 1 Fuser page count has exceeded life The fuser thermistor has failed Replace the fuser unit assembly if problem remains 924 75 Open fuser thermistor check Fuser type 2 Fuser page count has exceeded life The fuser thermistor might be faulty Replace the fuser unit ass...

Page 125: ...lled 2 Ensure the proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem 925 25 Incorrect fuser or fuser lamp detected Fuser type 2 The machine detected a 115 V lamp in a 220 V machine The fuser lamp has an excessive wattage rating 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the proper voltage fuser is installed...

Page 126: ... 2 Ensure the proper voltage fuser is installed in the machine 3 Replace the fuser unit assembly if problem 925 52 Incorrect fuser or fuser lamp detected Fuser type 1 Fuser page count has exceeded life The machine detected a 115 V lamp in a 220 V machine The fuser lamp has an excessive wattage rating 1 Turn the machine off on and ensure the fuser unit assembly is properly installed 2 Ensure the pr...

Page 127: ...ctions 2 Check the connections on the main cooling fan 3 Replace the main cooling 927 02 Print cartridge cooling fan failure The cooling fan is obstructed or has failed 1 Check for cooling fan obstructions 2 Check the connections on the main cooling fan 3 Replace the print cartridge 927 03 Main cooling fan control failure The main cooling fan does not reach the specified speed 4 Check for cooling ...

Page 128: ...artridge cooling fan does not reach the specified speed 1 Check for cooling fan obstructions 2 Check the connections on the main cooling fan 3 Replace the print cartridge 927 14 Print cartridge cooling fan underspeed failure The Print cartridge cooling fan does not reach the specified speed 1 Check for cooling fan obstructions 2 Check the connections on the main cooling fan 3 Replace the print car...

Page 129: ...oes not provide toner level feedback or the print cartridge is damaged 1 Check the toner pulse wheel on the print cartridge for damage and replace the print cartridge if needed 2 Check the sensor toner empty for proper 929 03 Sensor toner empty sensor failure The sensor toner empty does not provide toner level feedback or the print cartridge is damaged 1 Check the toner pulse wheel on the print ca...

Page 130: ... Check all connections on the system card assembly 2 Check all connections on the main drive motor assembly 3 Replace the main drive motor assembly Go to 4 Replace the system card assembly if problem 936 11 Main drive motor assembly failure No halls detected at motor start Motor type 1 The main drive motor assembly may be faulty or has failed 1 Check all connections on the system card assembly 2 C...

Page 131: ...has failed 1 Check all connections on the system card assembly 2 Check all connections on the main drive motor assembly 3 Replace the main drive motor assembly Go to 4 Replace the system card assembly if problem 936 31 Main drive motor assembly failure No lock detected at motor start for motor ID Motor type 1 The main drive motor assembly may be faulty or has failed 1 Check all connections on the ...

Page 132: ...ty or has failed 1 Check all connections on the system card assembly 2 Check all connections on the main drive motor assembly 3 Replace the main drive motor assembly Go to 4 Replace the system card assembly if problem 936 91 Main drive motor assembly failure Stall detected during speed control Motor type 1 The main drive motor assembly may be faulty or has failed 1 Check all connections on the sys...

Page 133: ...e faulty or has failed 1 Check all connections on the system card assembly 2 Check all connections on the main drive motor assembly 3 Replace the main drive motor assembly Go to 4 Replace the system card assembly if problem 937 51 Main drive motor assembly failure Over speed detected during position control Motor type 1 The main drive motor assembly may be faulty or has failed 1 Check all connecti...

Page 134: ...duplex assembly Warning Ensure that the metal frame of the internal duplex assembly is properly grounded to the metal frame of the LVPS with a jumper wire as shown in the graphic below If the jumper wire is NOT present install the 40X7028 internal duplex grounding kit This should only be done for machines with an installed internal duplex assembly 1 Check all connections on the system card assembl...

Page 135: ... Check all connections on the main drive motor assembly 3 Replace the main drive motor assembly Go to 4 Replace the system card assembly if problem 945 xxx Image processing unit failure The image processing ASIC or DRAM has failed 1 POR the machine 2 If the problem remains replace the scanner controller card Go to Error code or message Error contents Description Action Possible repair actions asse...

Page 136: ...o to NVRAM mismatch failure service check 952 xx NVRAM failure A recoverable MVRAM Cyclic Redundancy Check CRC error occurred Power the machine off on to reset the error condition 953 xx NVRAM failure The NVRAM chip has failed on the scanner interface card assembly Replace the scanner interface card assembly 954 xx NVRAM failure NVRAM chip failure with system card assembly Replace the system card ...

Page 137: ...Memory Error Slot 2 RAM is bad Replace the appropriate memory module 963 xx Memory failure RAM Memory Error Slot 3 RAM is bad Replace the appropriate memory module 964 xx Emulation failure The download Emulation Cyclic Redundancy Check CRC detected a failure 1 1 Disable the Download Emulation Program the download emulation into the firmware card again 2 Replace the system card assembly if problem ...

Page 138: ...Replace the HCIT tray lift motor drive motor assembly if 990 53 HCIT tray lift motor ramp error The HCIT tray lift motor does not reach the specified speed at the specified time 1 Check for obstruction in the HCIT tray lift area 2 Check the connections on the HCIT tray lift motor assembly for proper connection 3 Replace the HCIT tray lift drive motor assembly if 990 54 HCIT tray lift motor lost en...

Page 139: ...d properly Replace the Sensor input Replace the connection Step Check Yes No 1 Check the sensor fuser output for damage Is the above component free from damage Go to step 2 Replace fuser unit assembly 2 1 Enter the diagnostic mode 2 Select Base sensor test 4 Observe the line item exit Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or bl...

Page 140: ...Yes No 1 Check the sensor duplex input for damage Is the above component free from damage Go to step 2 Replace the sensor duplex input 2 1 Enter the diagnostic mode 2 Select Duplex sensor tests 3 Select Sensor test 4 Observe the line item input Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked The sensor is working properly Go t...

Page 141: ...ction Step Check Yes No 1 Check the sensor duplex exit for damage Is the above component free from damage Go to step 2 Replace the external duplex unit assembly 2 1 Enter the diagnostic mode 2 Select Duplex sensor tests 3 Select Sensor test 4 Observe the line item exit Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked The sensor...

Page 142: ...Go to step 2 2 Check the above sensor for proper connection Is the above sensor connected properly Replace the envelope feeder Replace the connection Step Check Yes No 1 1 Enter the diagnostic mode 2 Select Scanner tests 3 Select Sensor tests 4 Observe the line item Sensor ADF top door interlock Does the display on the operator panel change every time the sensing area of the above sensor is interr...

Page 143: ...ensor ADF closed interlock Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked The sensor is working properly Go to step 2 2 Check the above sensor for proper connection Is the above sensor connected properly Replace the sensor ADF closed interlock Replace the connection Go to Switch interlock ADF closed removal on page 4 84 ...

Page 144: ...or panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 4 Go to step 3 3 Check the sensor ADF sheet through for proper connection Is the above component properly connected Replace the sensor ADF sheet through Replace the connection 4 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assem...

Page 145: ...or the ADF separation roll assembly 3 Check the media path for contaminates Is the media path free of excess media dust and foreign objects such as paper clips and staples Go to step 4 Remove all contaminates from the media path 4 Check the ADF feed drive motor assembly for proper connection Is the above component properly connected Replace the ADF feed drive motor assembly Replace the connection ...

Page 146: ...s well as damage such as creases tears holes or excessive wear Go to step 2 Remove damaged original document and replace with a new undamaged original document Perform a ADF test If the problem remains go to step 2 2 Check the ADF rolls for wear Is the ADF feed pick roll assembly or the ADF separation roll guide assembly free of excess wear Go to step 3 Clean or replace the ADF feed pick roll asse...

Page 147: ...nection Is the above component properly connected Replace the ADF feed drive motor assembly Replace the connection 7 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to step 8 Problem solved 8 Perform a print test using the ADF Does the problem remain Contact next highest level of tech support Problem solved Use this pr...

Page 148: ...ep 5 5 Check the sensor ADF sheet through for proper connection Is the above component properly connected Replace the sensor ADF sheet through Replace the connection 6 Check the ADF feed drive motor assembly for proper connection Is the above component properly connected Replace the ADF feed drive motor assembly Replace the connection 7 Check the ADF transport drive motor assembly for proper conne...

Page 149: ...tor panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 4 Go to step 3 3 Check the sensor ADF 1st scan for proper connection Is the above component properly connected Replace the sensor ADF 1st scan Replace the connection 4 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to...

Page 150: ...4 Go to step 3 3 Check the sensor ADF 2nd scan for proper connection Is the above component properly connected Replace the sensor ADF 2nd scan Replace the connection 4 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to step 5 Problem solved 5 Perform a print test using the ADF Does the problem remain Contact next highe...

Page 151: ...e operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 6 Go to step 5 5 Check the sensor ADF 2nd scan for proper connection Is the above component properly connected Replace the sensor ADF 2nd scan Replace the connection 6 Check the ADF transport drive motor assembly for proper connection Is the above component properly connected Replace the AD...

Page 152: ...e the sensing area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 4 Check the sensor ADF media exit for proper connection Is the above component properly connected Replace the sensor ADF media exit Go to Go to Replace the connection 5 Check the ADF transport drive motor assembly for proper connection Is the above component properly connected Replace the ADF transport drive...

Page 153: ...ed or blocked Go to step 4 Go to step 3 3 Check the sensor ADF top door interlock for proper connection Is the above component properly connected Replace the sensor ADF top door interlock Replace the connection 4 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to step 5 Problem solved 5 Perform a print test using the A...

Page 154: ...n Replace the ADF controller card assembly Go to step 5 Problem solved 5 Perform a print test using the ADF Does the problem remain Contact next highest level of tech support Problem solved Use this procedure for the following jams 294 00 1 Check the media path Is the media path free of media or media fragments Go to step 2 Remove any media or media fragments 2 Check the sensor ADF media exit for ...

Page 155: ...ition Is the original document free of paper clips and staples as well as damage such as creases tears holes or excessive wear Go to step 2 Remove damaged original document and replace with a new undamaged original document Perform a ADF test If the problem remains go to step 2 2 Check the ADF rolls for wear Is the ADF feed pick roll assembly or the ADF separation roll guide assembly free of exces...

Page 156: ...roperly connected Replace the sensor ADF media exit Replace the connection 6 Check the ADF transport drive motor assembly for proper connection Is the above component properly connected Replace the ADF transport drive motor assembly Replace the connection 7 Place an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to step 8 Prob...

Page 157: ...ia path for contaminates Is the media path free of excess media dust and foreign objects such as paper clips and staples Go to step 4 Remove all contaminates from the media path 4 Check the sensor ADF media exit for proper operation 1 Enter the Diagnostics Menu 2 Touch SCANNER TESTS 3 Touch Sensor Tests 4 Observe the line sensor ADF media exit Does the display on the operator panel change every ti...

Page 158: ...e an undamaged document in the ADF and perform a ADF test Does the error remain Replace the ADF controller card assembly Go to step 8 Problem solved 8 Perform a print test using the ADF Does the problem remain Contact next highest level of tech support Problem solved Step Check Yes No Go to ADF transport drive motor bracket cable removal assembly w on page 4 77 Go to ADF controller card removal on...

Page 159: ...ep 4 4 Check the media tray pass through areas for obstructions Are the pass through areas in all the media trays free from obstructions Go to step 5 Remove obstructions 5 Check media origination Did the media originate from the MPF Go to step 6 Go to step 8 6 Check the MPF pick roll assembly Is the above component free of excess wear and contamination Go to step 7 Clean or replace assembly 7 Perf...

Page 160: ...t Duplex tests 3 Select sensor test 3 Observe the line item input Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 15 Replace the external duplex assembly 15 Check the sensor duplex exit for proper operation 1 Enter the diagnostic mode 2 Select Duplex tests 3 Select sensor test 3 Observe the line item exist Does the ...

Page 161: ... assembly Go to 22 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Use this procedure for the following jams 200 01 200 02 200 17 200 18 200 19 200 27 200 28 200 29 200 37 200 38 200 39 200 47 200 48 200 49 200 57 200 58 200 59 Step Check Yes No 1 Check the media size setup and tray guides for all media trays Does the media size in use match t...

Page 162: ... operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 8 Go to step 7 7 Check the above sensor for proper connection Is the above sensor connected properly Replace the fuser unit assembly Replace the connection 8 Perform a print test and check the main motor assembly Is the media properly transported and able to reach the sensor fuser output Rep...

Page 163: ...the media trays and the media path for partially fed media Are the media trays and the media path free from any partially fed pieces of media Go to step 7 Remove any pre staged or jammed media 7 Check the sensor input for proper operation 1 Enter the diagnostic mode 2 Select Base sensor test 3 Observe the line item input Does the display on the operator panel change every time the sensing area of ...

Page 164: ... the media size setup and tray guides for all media trays Does the media size in use match the size set for all media trays Go to step 2 Replace the media or change the media size setup 2 Check all the media trays for proper media installation Is the media properly installed in all the media trays Go to step 3 Remove and properly re install the media 3 Check the fuser unit assembly for damage and ...

Page 165: ...e for the following jams 202 01 202 02 202 07 202 10 202 11 202 12 202 26 202 27 202 32 202 34 202 35 202 36 202 37 202 51 202 52 202 57 202 59 202 60 202 61 202 62 202 76 202 77 202 82 202 84 202 85 202 86 202 87 Step Check Yes No 1 Check the media size setup and tray guides for all media trays Does the media size in use match the size set for all media trays Go to step 2 Replace the media or cha...

Page 166: ...e the fuser unit assembly Replace the connection 7 Check the redrive assembly for damage Is the above component free from damage Go to step 8 Replace the redrive assembly 8 Perform a print test and check the redrive motor assembly for proper operation Does the above component operate properly Go to step 9 Replace the redrive motor assembly 9 Perform a print test Does the problem remain Contact nex...

Page 167: ...rint test Does the problem remain Contact next highest level of tech support Problem solved Use this procedure for the following jams 201 04 201 06 201 29 201 31 201 54 201 56 201 79 201 81 Step Check Yes No 1 Check the media size setup and tray guides for all media trays Does the media size in use match the size set for all media trays Go to step 2 Replace the media or change the media size setup...

Page 168: ...sembly for damage Is the above component free from damage Go to step 9 Replace the transfer roll assembly 9 Perform a print test and check the main motor assembly Is the media properly transported and able to reach the sensor fuser output Go to step 10 Replace the main drive motor assembly 10 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Use...

Page 169: ...p 2 Open then properly close the door assembly rear 2 Check the fuser access door Is the above component properly closed Go to step 3 Open then properly close the fuser access door 3 Check media origination Did the media originate from the internal duplex Go to step 4 Go to step 10 4 Check the internal duplex media path for obstructions Is the above component free from obstructions Go to step 5 Re...

Page 170: ... Replace the duplex drive motor assembly 11 Check the external duplex media path for obstructions Is the above component free from obstructions Go to step 12 Remove obstructions 12 Check the external duplex unit assembly for proper installation Is the above component properly installed Go to step 13 Remove then properly re install the external duplex unit assembly 13 Check the sensor duplex input ...

Page 171: ... connection Is the above sensor connected properly Replace the sensor duplex input Replace the connection 6 Check the aligner assembly for obstructions Is the above component free from obstructions Go to step 7 Remove obstructions 7 Check the external duplex media path for obstructions Is the above component free from obstructions Go to step x Remove obstructions 8 Check the external duplex unit a...

Page 172: ... of the above sensor is interrupted or blocked Go to step 7 Go to step 4 4 Check the above sensor for proper connection Is the above sensor connected properly Replace the sensor duplex input Replace the connection 5 Check the media path for partially fed or jammed media Is the media path free from partially fed or jammed media Go to step 6 Remove any pre staged or jammed media 6 Check the sensor d...

Page 173: ...h new Go to step 4 4 Check the media tray pass through areas for obstructions Are the pass through areas in all the media trays free from obstructions Go to step 5 Remove obstructions 5 Check the two pick roll assemblies in the media tray being picked from Are the above components free of excess wear and Go to step 6 Clean or replace the pick roll assembly 6 Check the appropriate media tray sensor...

Page 174: ...r all media trays Does the media size in use match the size set for all media trays Go to step 2 Replace the media or change the media size setup 2 Check the media tray pass through areas for obstructions Are the pass through areas in all the media trays free from obstructions Go to step 3 Remove obstructions 3 Check the appropriate media tray sensor pass through for proper operation 1 Enter the d...

Page 175: ...e from partially fed or jammed media Go to step 2 Remove any pre staged or jammed media 2 Check the appropriate media tray sensor pass through for proper operation 1 Enter the diagnostic mode 2 Select Input tray tests 3 Sensor test 4 Select the appropriate tray number 3 Observe the line item pass through for the appropriate media tray Does the display on the operator panel change every time the se...

Page 176: ... step 5 Go to step 4 4 Check the above sensor for proper connection Is the above sensor connected properly Replace the output option Replace the connection Step Check Yes No 1 Check the output option for proper installation Is the above component properly installed Go to step 2 Remove then reinstall the output option 2 Check for obstructions in the media path between the Sensor stapler pass throug...

Page 177: ...tep Check Yes No 1 Check the output option for proper installation Is the above component properly installed Go to step 2 Remove then reinstall the output option 2 Check for obstructions in the media path between the base machine and the output option Is the media path free from obstructions Go to step 3 Remove obstructions 3 Check the sensor output pass through for proper operation 1 Enter the di...

Page 178: ...ng area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 4 Check the above sensor for proper connection Is the above sensor connected properly Replace the sensor output pass through Replace the connection 5 Perform a print test using the output option Does the error continue Replace the output option Problem solved Ste p Check Yes No 1 Check the media path for partially fed ...

Page 179: ... Check the sensor mailbox empty for proper operation 1 Enter the diagnostic mode 2 Select Output bin tests 3 Select Sensor test 4 Select Output bin x 5 Observe the line item mailbox empty Does the display on the operator panel change every time the sensing area of the above sensor is interrupted or blocked Go to step 5 Go to step 4 4 Check the above sensor for proper connection Is the above sensor...

Page 180: ...r continue Replace the output option Problem solved Step Check Yes No 1 Check the media path for partially fed or jammed media Is the media path free from partially fed or jammed media Go to step 2 Remove any pre staged or jammed media 2 Check the sensor mailbox empty for proper operation 1 Enter the diagnostic mode 2 Select Output bin tests 3 Select Sensor test 4 Select Output bin x 5 Observe the...

Page 181: ...tion Is the above sensor connected properly Replace the sensor toner empty Replace the connection Step Check Yes No 1 Check the sensor scanner HP for proper installation Is the above component properly installed Go to step 2 Reinstall the sensor scanner HP 2 Check the sensor scanner HP for proper operation 1 Enter the diagnostic mode 2 Select Scanner tests 3 Select Sensor tests 4 Observe the line ...

Page 182: ...ethod of troubleshooting as long as the machine is booted into diagnostic mode or is operating in diagnostic mode Once a component has been installed in a machine and powered up into user mode it cannot be used in another machine It must be returned to the manufacturer Step Check Yes No 1 Check the operator panel assembly Was the operator panel assembly recently replaced Go to step 3 Go to step 2 ...

Page 183: ...int Low contrast on page 2 152 Blank print no print Blank print no print on page 2 154 Solid black Solid black on page 2 156 Vertical blank lines White stripes in media transport direction Vertical lines and bands process direction on page 2 157 Horizontal band Horizontal white stripes or bands side to side direction on page 2 158 Vertical stripes Vertical stripes process direction on page 2 159 H...

Page 184: ...ce the transfer roll assembly 4 Check the print cartridge for proper installation Is the print cartridge properly installed Go to step 5 Inspect clean and reinstall replace the print cartridge 5 Check the laser beam route Check for debris between the printhead assembly and the PC drum Is the laser beam route free of debris and the glass window in the printhead assembly free of contamination Go to ...

Page 185: ...nnection Is the above component properly connected Replace the printhead assembly Go to Replace the connections 8 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Step Check Yes No Printhead assembly removal on page 4 34 ...

Page 186: ...l the transfer roll assembly 4 Check the left and right transfer roll bracket Are the above components free from damage Go to step 5 Replace the left and or right transfer roll brackets 5 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 6 Replace the transfer roll assembly 6 Check the print cartridge for proper installation Is th...

Page 187: ...he above component properly connected Replace the HVPS card assembly Replace the connections 9 Check the printhead assembly for proper connection Is the above component properly connected Replace the printhead assembly Go to Replace the connections 10 Check the system card assembly for proper connection Is the above component properly connected Replace the system card assembly Replace the connecti...

Page 188: ...tallation Is the above component properly installed Go to step 3 Inspect clean and reinstall replace the print cartridge 3 Check the charge roll HVPS card assembly connections Is the above component properly connected Replace the HVPS card assembly Replace the connection 4 Check the system card assembly for proper connection Is the above component properly connected Replace the system card assembl...

Page 189: ...e debris or clean the printhead assembly window 4 Check the print cartridge for proper installation Is the above component properly installed Go to step 5 Inspect clean and reinstall replace the print cartridge 5 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 6 Replace the transfer roll assembly 6 Check the printhead assembly f...

Page 190: ...r level normal Go to step 4 Replace the print cartridge 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the printhead assembly for proper connection Is the above component properly connected Replace the printhead assembly Replace the connections 6 Perform a print test Does the probl...

Page 191: ...ssembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the print cartridge for proper installation Is the above component properly installed Go to step 6 Inspect clean and reinstall replace the print cartridge 6 Check the heat roll and pressure roll Remove the fuser unit assembly CAUTION Allow the fuser unit down Is...

Page 192: ...mination 3 Check the print cartridge for proper installation Is the above component properly installed Go to step 4 Inspect clean and reinstall replace the print cartridge 4 Check the charge roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the charge roll assembly 5 Check the transfer roll assembly for contamination and wear Is the above ...

Page 193: ...e fuser unit assembly Go to step 7 7 Check the HVPS card assembly for proper connection Is the above component properly connected Replace the HVPS card assembly Replace the connections 8 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Step Check Yes No Go to Fuser unit assembly assembly to cool removal on page 4 15 Go to HVPS card assembly rem...

Page 194: ...he printhead assembly free of contamination Go to step 4 Remove debris or clean the printhead assembly window 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the printhead installation Is the above component properly installed Go to step 6 Reinstall and adjust the printhead assembly...

Page 195: ... assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the charge roll assembly 5 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 6 Replace the transfer roll assembly 6 Check the heat roll and pressure roll Remove the fuser unit assembly CAUTION Allow the fuser unit down Is there...

Page 196: ...e above component properly installed Go to step 8 Reinstall and adjust the printhead assembly Go to 8 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Step Check Yes No Printhead assembly removal on page 4 34 ...

Page 197: ...es the error continue Go to step 2 Problem solved 2 Check the heat roll and pressure roll Remove the fuser unit assembly CAUTION Allow the fuser unit down Is there contamination or cracks on the heat roll and or pressure roll Replace the fuser unit assembly Go to step 4 3 Perform a print test Does the problem remain Contact next highest level of tech support Problem solved Leading edge Trailing ed...

Page 198: ... cartridge 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the HVPS card assembly for proper connection Is the above component connected properly Go to step 6 Replace the connections 6 Check the printhead installation Is the above component properly installed Go to step 7 Reinstall ...

Page 199: ...roblem solved 3 Check for obstructions in the area of the media feed units Are the media feed unit assembly free from any obstructions Go to step 4 Remove obstructions 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the alignment assembly for proper adjustment Does the problem remai...

Page 200: ...or continue Go to step 3 Problem solved 3 Check the media condition Load new dry recommended media Re print the defective image Does the error continue Go to step 4 Problem solved 4 Check the transfer roll assembly for contamination and wear Is the above component free of excess wear and Go to step 5 Replace the transfer roll assembly 5 Check the alignment assembly for proper adjustment Does the p...

Page 201: ...unit assembly CAUTION Allow the fuser unit down Is there contamination or cracks on the heat roll and or pressure roll Replace the fuser unit assembly Inspect the machine for obstructions in the media path Step Check Yes No Go to Fuser unit assembly assembly to cool removal on page 4 15 ...

Page 202: ...AUTION Allow the fuser unit down Is there contamination or cracks on the heat roll and or pressure roll Replace the fuser unit assembly Go to step 4 4 Check the LVPS card assembly for proper connection Is the above component connected properly Replace the LVPS card assembly Remove then reinsert the LVPS card assembly 5 Perform a print test Does the problem remain Replace the system card assembly P...

Page 203: ...ed by a particular roll In this case measure the interval on the print test and check the relation to the roll in the printer The interval does not necessarily match circumference of the roll Dark print Faint print Low contrast on page 2 152 Vertical stripes Vertical stripes process direction on page 2 159 Horizontal stripes Horizontal stripes side to side direction on page 2 160 Spots Spots on pa...

Page 204: ...rrors in the scanner unit assembly Go to step 3 3 Check the white strip on the bottom of the large platen glass Is the white strip contaminated Clean the white strip and POR the machine Go to step 4 4 Check the scanner lens Is the scanner lens contaminated Clean the scanner lens Go to step 5 5 Perform a print test using the ADF scanner unit assemblies Does the error continue Replace the CCD card l...

Page 205: ...signs of dust Clean the three mirrors in the scanner unit assembly Go to step 3 3 Check the white strip on the bottom of the large platen glass Is the white strip contaminated Clean the white strip and POR the machine Go to step 4 4 Perform a print test using the scanner unit assembly Does the error continue Replace the scanner unit assembly Problem solved Leading edge Trailing edge Leading edge T...

Page 206: ... glass cover Go to step 2 2 Check the three mirrors in the scanner unit assembly Are the three mirrors contaminated or show signs of dust Clean the three mirrors in the scanner unit assembly Go to step 3 Step Check Yes No Leading edge Trailing edge Leading edge Trailing edge Go to Scanner controller card removal assembly models X651 Go to Scanner platen glass X656 on platen glass page 4 140 or Sca...

Page 207: ...ing the scanner CCD assembly Does the error continue Replace the scanner CCD assembly Problem solved 5 Perform a print test using the flatbed scanner assembly Does the error continue Replace the scanner controller card assembly Problem solved Step Check Yes No Go to Scanner CCD assembly removal on page 4 91 assembly Go to Scanner controller card models X651 on page 4 132 X654 and X656 removal X652...

Page 208: ...k for obstructions in the area of the media feed path in the ADF Is the media feed path free from any obstructions Go to step 4 Remove obstructions 4 Is the ADF left cover assembly properly and evenly closed Go to step 5 Open then properly close the ADF left cover assembly 5 Check the ADF pick roll assembly for damage and wear Is the ADF feed pick roll assembly free from damage Go to step 6 Replac...

Page 209: ...ver assembly 4 Check the ADF pick roll assembly for damage and wear Is the ADF feed pick roll assembly free from damage Go to step 5 Replace the ADF feed pick roll assembly 5 Check the ADF separator roll Is the separator roll free from damage and wear Go to step 6 Replace the separator roll 6 Check the ADF controller card assembly Replace the ADF controller card assembly Perform a print test using...

Page 210: ...y state Go to step 5 Go to step 4 4 Change the printer status to online Did this fix the issue Problem resolved Go to step 5 5 Does the IP address displayed on the network settings page match the IP address in the port of the drivers using the printer Go to step 10 Go to step 6 6 Does the LAN use DHCP Note A printer should use a static IP address on a network Go to step 7 Go to step 9 7 Are the fi...

Page 211: ... the wireless card seated correctly Go to step 20 Go to step 19 19 Properly reseat the wireless card Did this fix the problem Problem resolved Go to step 20 20 Is the antenna damaged Go to step 22 Go to step 21 21 Replace the antenna Did this fix the problem Problem resolved Go to step 22 22 Verify that the antenna is properly connected to the wireless card Is it connected correctly Go to step 24 ...

Page 212: ...2 180 Service Manual ...

Page 213: ...n or home screen pressing causes an error beep 4 Back In the Copy menu press to delete the right most digit of the value in the Copy Count The default value of 1 appears if the entire number is deleted by pressing numerous times In the Fax Destination List press to delete the right most digit of a number entered manually You can also press to delete an entire shortcut entry Once an entire line is ...

Page 214: ...If pressed while a job is scanning the button has no effect 7 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 8 Stop Stops all printer activity A list of options is offered once Stopped appears on the display Display item Descrip...

Page 215: ...onfidential print jobs Job names for held jobs excluding confidential print jobs Profile names Bookmark container or job names USB container or job names for supported extensions only Held Jobs Opens a screen containing all the held jobs Lock Device This button appears on the screen when the printer is unlocked and Device Lock out Personal Identification Number PIN has been set Touching this butto...

Page 216: ...our screens and buttons may vary from those shown Sample touch screen Button Function Home Returns to the home screen Scroll down Opens a drop down list Left scroll decrease Scrolls to another value in decreasing order Right scroll increase Scrolls to another value in increasing order Left arrow Scrolls left ...

Page 217: ...o the previous screen Button Function Down arrow Moves down to the next screen Up arrow Moves up to the next screen Unselected radio button This is an unselected radio button The radio button is gray to show it is unselected Selected radio button This is a selected radio button The radio button is blue to show it is selected Button Function Submit ...

Page 218: ...FTP E mail send Each heading has a list of jobs shown in a column under it which can show only three jobs per screen Each job appears as a button which you can touch to access information about the job If more than three jobs exist in a column then an arrow appears enabling you to scroll through the jobs Continue Touch this button when more changes need to be made for a job or after clearing a pap...

Page 219: ...roup is active all host interfaces are offline information Configuration Menu 1 Turn off the printer 2 Press and hold the 2 and 6 buttons simultaneously for about 10 seconds 3 Turn on the printer 4 Release the buttons after 10 seconds The Configuration Menu group contains a set of menus settings and operations which are infrequently required by a user Generally the options made available in this m...

Page 220: ...nostics Menu tests Top Margin Bottom Margin Left Margin Right Margin PRINT TESTS Tray 2 if installed Tray 3 if installed Tray 4 if installed Tray 5 if installed MP Feeder Envelopes MP Feeder if installed HARDWARE TESTS USB HS Test Mode REGISTRATION See Registration printer on page 3 11 Quick Test See Quick Test on page 3 12 Tray 1 See Input source tests on page 3 13 Printing Print Quality Pages Se...

Page 221: ...TS Diagnostics Menu tests Continued Quick Test See Quick Test duplex on page 3 16 Sensor Test See Sensor Test duplex on page 3 17 Motor Test See Motor Test duplex on page 3 17 Top Margin See Top Margin duplex on page 3 17 Duplex Feed 1 See Duplex Feed 1 on page 3 18 Duplex Feed 2 See Duplex Feed 2 on page 3 18 Feed Tests See Feed Tests input tray on page 3 19 Sensor Tests See Sensor Test input tra...

Page 222: ...23 Edge To Edge See Edge to Edge on page 3 23 Enable Edge to Edge Copy See Enable Edge to Edge Copy on page 3 23 EP Defaults See EP Defaults on page 3 24 Fuser Temp See Fuser Temperature Fuser Temp on page 3 24 Fuser Page Count See Fuser Page Count on page 3 24 Warm Up Time See Warm Up Time on page 3 24 Transfer See Transfer on page 3 25 Print Contrast See Print Contrast on page 3 25 Charge Roll S...

Page 223: ...age up and decreases the top margin Bottom Margin 20 to 20 Each increment causes approximately 0 55 mm shift in the bottom margin A positive change compresses the image so it appears to move down the page and a negative change moves the image up 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 posi...

Page 224: ...rints a Quick Test page from the appropriate paper tray While the Quick Test page prints Printing Alignment Page appears on the LCD Quick Test The Quick Test contains the following information Device information Printer margin settings Scanner margin settings Alignment diamonds at the top bottom and each side Horizontal lines for skew adjustment General printer information including current page c...

Page 225: ...e Print Test Page always prints on one side of the paper regardless of the duplex setting or the presence of a duplex option Touch Back to return to PRINT TESTS Printing Quality Pages The purpose of this diagnostic function is to allow printing of the print quality test pages with the toner cartridge lockout function disabled The print quality pages consist of four pages Page one contains a mixtur...

Page 226: ...s for the QUALITY MENU settings used to print the pages HARDWARE TESTS Select the following Hardware Tests from this menu Panel Test Button Test DRAM Test USB HS Test Mode Panel Test This test automatically toggles each pixel of the touchscreen through every contrast level beginning with the darkest and on to the brightest This test continues until you press Stop Button Test The Button Test verifi...

Page 227: ...e maximum pass count or fail count is reached the test is stopped the power indicator is turned on solid and the final results display To stop the test before completion turn the MFP off CACHE Test This test is used to verify the printer processor cache To run the CACHE Test 1 Touch to select CACHE TEST from HARDWARE TESTS The message CACHE Test Testing displays Then the message Resetting Printer ...

Page 228: ...ed The printer attempts to print the Quick Test Page from the default paper source If the default paper source only supports envelopes then the page is printed from Tray 1 Check the Quick Test Page for the correct offset between the placement of the first scan line on the front and back side of a duplexed sheet The single test stops automatically when a single duplex sheet is printed and the conti...

Page 229: ...mine whether or not the duplex sensors and switches are working correctly The test allows you to actuate the duplex input sensor located in the back part of the duplex unit and the duplex exit sensor located in the return paper path 1 Select Sensor Test from DUPLEX TESTS The message Sensor Test Testing displays 2 Manually actuate each of the duplex sensors When the sensor switch is closed CL close...

Page 230: ...or turns on solid 2 Remove the media from the duplex unit and clear the message on the operator panel by pressing Stop Duplex Feed 2 This test feeds a blank sheet of paper to the duplex paper stop position 2 This test can be run using any of the supported paper sizes To run the Duplex Feed 2 Test 1 Touch to select Duplex Feed 2 from DUPLEX TESTS The power indicator blinks while the paper is feedin...

Page 231: ... to determine if the input tray sensors are working correctly To run the Input Tray Sensor Test 1 Touch to select the Sensor Test from INPUT TRAY TESTS 2 Touch to select the input source from the sources displayed on the Sensor Test menu All installed sources are listed 3 Select the sensor to test Various sources have different combinations of sensors See the table below sensor selected Open displ...

Page 232: ...test is used to verify if the standard bin sensor is working correctly To run the Sensor Test for the standard bin 1 Touch to select Sensor Test from OUTPUT BIN TESTS 2 Touch to select Standard Bin from Sensor Tests 3 Manually actuate the bin sensor by moving the flag in and out of the sensor and the display changes The following screen is displayed Bin Empty empty or Bin Empty full 4 Press Stop t...

Page 233: ...Press Stop to return to the Device Tests menu Disk Test Clean Warning This test destroys all data on the disk and should not be attempted on a good disk Also note that this test may run approximately 1 hours depending on the disk size To run the Disk Test Clean Test 1 Touch to select Disk Test Clean from the Device Tests menu Contents will be lost Continue message displays to warn the user that al...

Page 234: ...d data may be lost It cannot be undone Printed Page Count The page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Permanent Page Count The permanent page count can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Serial Number The serial number can only be viewed and cannot be changed Touch Back to return to Diagnostics Menu Eng...

Page 235: ... ID 3 Touch the keyboard icon to display a keyboard with 1 through 0 and a through f The current values for Configuration ID 1 and Configuration ID 2 are displayed Use keys to type the numbers for the two configuration IDs Use the left arrow to move over a digit from the right of the number toward the left When the numbers are correct touch Submit If you have a question touch the question mark ico...

Page 236: ...s Fuser Temperature Fuser Temp This adjustment can be used to help solve some customer problems with paper curl on low grade papers and problems with letterheads on some types of media The fuser temperature can be adjusted to Normal Lower Lowest The default is Normal Touch Back to return to Diagnostics Menu Fuser Page Count The fuser page count can only be viewed and cannot be changed Touch Back t...

Page 237: ...iagnostics Menu Auto Dark Adjust The settings are Enable and Disable REPORTS Menu Settings Page This enables you to print the Menu Settings Page The report prints the Diag Menu to include Registration Print Tests Hardware Tests Duplex Tests Input Tray Tests Output Bin Tests Device Tests Printer Setup EP Setup Reports Event Log Development Menu and Scanner Tests EVENT LOG Display Log The event log ...

Page 238: ... some cases To print the event log Touch to select Print Log from EVENT LOG Clear Log Use Clear Log to remove the current information in the Event Log This affects both the viewed log and the printed log information 1 Touch to select Clear Log from the Event Log menu 2 Touch to select Yes to clear the Event Log or touch to select NO to exit the Clear Log menu If YES is selected Deleting EVENT LOG ...

Page 239: ... displays the setting s current value setting s current value Use the arrows to select from Letter Legal or A4 3 Touch START to begin Running Flatbed displays Press 4 to exit the test 4 Touch Back to return to the Diagnostics Menu Sensor Tests The following tests are available Sensor ADF document set Sensor ADF closed interlock Sensor FB scanner HP Sensor ADF sheet through Sensor ADF top door inte...

Page 240: ... page 3 33 Min Copy Memory See Min Copy Memory on page 3 34 NumPad Job Assist See NumPad Job Assist on page 3 34 Format Fax Storage See NumPad Job Assist on page 3 34 ADF Edge Erase See ADF Edge Erase on page 3 34 Scanner Manual Registration See Scanner Manual Registration on page 3 35 FB Edge Erase See FB Edge Erase on page 3 35 Disable Scanner See Disable Scanner on page 3 36 Paper Prompts See D...

Page 241: ...fter an 80 Scheduled Maintenance message displays and a maintenance kit is installed To view the maintenance page count touch to select Maintenance Counter Value from the Configuration Menu The value is displayed and cannot be changed Touch Back to return to the main Configuration Menu Reset Maintenance Counter After scheduled maintenance the servicer needs to reset the page counter To reset the m...

Page 242: ...enu page To print the Print Quality Test Pages touch to select Print Quality Pages from Configuration Menu The message Printing Quality Test Pages is displayed The following is printed on the first page Device Information to include page count installed memory processor speed serial number engine ID system card ID and printer revision levels Cartridge Information Printer Margin Settings Scanner Ma...

Page 243: ...rinted from DIAGNOSTICS mode does include this information SIZE SENSING This setting controls whether the printer automatically registers the size of paper installed in an input source with size sensing Maintenance Counter Value USB Scan to Local Print Quality Pages Reports SIZE SENSING Panel Menu PPDS Emulation Factory Defaults Energy Conserve Min Copy Memory NumPad Job Assist Fax Storage Locatio...

Page 244: ...the setting s name in the header and setting s current value below the header row Touch or to change the setting The selections are On and Off The default is Enable 3 Touch Submit to save your change Touch Back to exit without changing the value PPDS Emulation This menu item allows the user to enable or disable PPDS emulation data stream When this setting is enabled the following settings are also...

Page 245: ...y state Restoring Factory Defaults and then Resetting the Device are displayed 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 If On is set in Energy Conserve the Power Saver feature cannot be disabled 1 Touch to select Energy Conserve from the Co...

Page 246: ...latile storage used for storing faxes To change this setting touch to select Format Fax Storage from the Configuration Menu Formatting Fax Flash DO NOT POWER OFF appears on the LCD while the format operation is active Note If an advanced password has been established you must enter this password in order to change the setting Fax Storage Location To change this setting touch to select Fax Storage ...

Page 247: ...ader and setting s current value below the header row 2 Touch to increase the value or to decrease the value The values are 0 through 6 The default is 3 3 Touch Submit to save the change Touch Back to cancel and return to the Configuration Menu Scanner Manual Registration To perform the Scanner Manual Registration 1 Touch to select Scanner Manual Registration from the Configuration Menu The panel ...

Page 248: ...this setting touch to select Disable Scanner from the Configuration Menu 1 Touch or to change the setting The settings are Enable Disable and ADF Disable 2 Touch Submit to save your change Touch Back to exit without changing the value Paper Prompts When a tray is out of the indicated paper size a prompt is sent to the user to load paper in a tray This setting controls the tray the user is directed...

Page 249: ... for Prompts from the Configuration Menu The panel displays the setting s name in the header and setting s current value below the header row 2 Touch or to change the value The values are Prompt user default Continue and Use current 3 Touch Submit to save the change Touch Back to exit without changing the value ...

Page 250: ...s been established you must enter this password in order to change the setting If no advanced password exists you can establish one by using the keyboard that appears on the LCD 2 Touch next to either Enable or Disable If you remove an encrypted disk from a device and then try to install another disk Disk Corrupted Reformat appears on the LCD You can format the newly installed disk or remove it fr...

Page 251: ... font data For example at the default 24 all text in font sizes 24 and less will use the high frequency screens The values for this setting range from 0 to 150 and the default value is 24 This setting affects PostScript PCL and XL To change this setting 1 Touch to select Font Sharpening from the Configuration Menu 2 Touch to increase the value or to decrease the value 3 Touch Submit to save the ch...

Page 252: ...ancel and return to the Configuration Menu Key Repeat Rate This is the number of times per second that a repeating key will repeat The range is 1 100 with a default of 15 times per second To change this setting 1 Touch to select Key Repeat Initial Delay from the Configuration Menu 2 Touch to increase the value or to decrease the value 3 Touch Submit to save the change Touch Back to cancel and retu...

Page 253: ...Diagnostic aids 3 41 Exit Configuration Menu Touch Exit Config Menu to exit the Configuration Menu The printer performs a POR and the printer returns to the ready mode Exit Config Menu ...

Page 254: ...rpose feeder 5 550 sheet tray Tray 1 6 550 sheet tray Tray 2 7 Optional output bin 1 3 4 5 6 2 2 7 CAUTION Floor mounted configurations require additional furniture for stability You must use either a printer stand or printer base if you are using a 2000 sheet drawer Certain other configurations also must have a printer stand or printer base More information is available on our Dell Web site at ww...

Page 255: ...sor input PC drum Standard bin full actuator and sensor standard bin full Diverter Sensor duplex input Sensor fuser output Sensor narrow media Pick arm assembly Sensor option pass through Models X651 X652 5535dn X654 and X656 paper path rolls and sensors ...

Page 256: ...cal components and rolls Media tray assembly It is necessary to adjust the media tray rear guide and media tray side guide of the media tray assembly to match the media size PC cartridge Sensor input PC drum Standard bin full actuator and sensor standard bin full Diverter Sensor duplex input Sensor fuser output Sensor narrow media Pick arm assembly Sensor option pass through ...

Page 257: ...d hold it in position Side guide The media tray assembly is designed so it can adapt to the media width in the media feed direction by moving the side guide to the left or right Wear strips The wear strips are designed to provide a fixed resistance to ensure that a single piece of paper is properly fed out of the media tray There are several types of wear strips available for custom or hard to fee...

Page 258: ...3 46 Service Manual Media tray assembly Wear strips Side guides End guides ...

Page 259: ...d it picks very aggressively No customer adjustments are necessary therefore no special trays are needed for card stock or labels The gearing in the arm is designed so the input torque from the motor produces a movement about the pivot of the arm This movement produces a downward force at the pick rolls The friction between the pick roll and the paper produces a frictional locking condition If the...

Page 260: ...ow Multi purpose feeder MPF The MPF is a mechanical unit supplying media to the printer The driving force from the main drive motor drive motor is transmitted to the MPF pick roll to feed media MPF feed roll The MPF pick roll feeds the media set on the MPF into the printer MPF pick solenoid The MPF pick solenoid transmits the driving force from the main drive motor assembly to the MPF pick roll MP...

Page 261: ... 210 x 297 mm 8 3 x 11 7 in x x x x A5 148 x 210 mm 5 8 x8 3in x x x A61 2 105 x 148 mm 4 1 x 5 8 in x J15 B5 182 x 257 mm 7 2 x 10 1 in x x x Letter 216 x 279 mm 8 5 x 11 in x x x x Legal 216 x 356 mm 8 5 x14 in x x x x Executive 184 x 267 mm 7 3 x 10 5 in x x x Oficio1 216 x340 mm 8 5 x 13 4 in x x x Folio1 216 x 330 mm 8 5 x 13 in x x x Statement1 140 x 216 mm 5 5 x8 5 in x x Universal3 4 138 x...

Page 262: ...urned off 2 Only the standard exit bin supports this size 3This size setting formats the page for 216 x 356 mm 8 5 x 14 in unless the size is specified by the software application 4 To support duplexing the Universal width must be between 148 mm 5 8 in and 216 mm 8 5 in Universal length must be between 182 mm 7 2 in and 356 mm 14 in Paper size Dimensions 250 or 550 sheet trays standard or optional...

Page 263: ...t path Alignment assembly The alignment assembly is used to feed the media through the input path and to ensure that media is fed through the machine in a perfectly straight manner and not in a skewed manner The alignment assembly can be adjusted to correct media skew issues and should always be adjusted when it is replaced Aligner assembly Sensor input ...

Page 264: ...ansfer 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 Transfer roll ...

Page 265: ...rs and windows The laser beam then arrives at the photo conductor drum surface 3 SOS card assembly when a laser beam hits the SOS sensor on the SOS card assembly the beam is converted to an electrical signal SOS signal and detects the initial position where a scan starts on each line When a laser beam is scanned across the photoconductor drum surface from one end to the other while turning on and ...

Page 266: ...3 54 Service Manual Conceptual diagram of an image created by scanning Fuser Fuser unit assembly ...

Page 267: ...ponents Heat roll The heat roll is a hollow metal tube with a coated surface This tube is heated by the inner heater lamp The heat is applied to the media passing between the heat roll and pressure roll fusing the toner on the media ...

Page 268: ...ff the circuits of the main heater lamp and sub heater lamp Thermistor The thermistor monitors the surface temperature of the media feed portion of the heat roll to control on off of the main heater lamp and sub heater lamp Sensor fuser output The sensor fuser output detects the arrival of media at the detection point in the exit area of the fuser and also detects the ejection of media from this p...

Page 269: ...er unit assembly has a life of 300K Type 2 fuser unit assembly In the type 2 fuser unit assembly the detacs which are used to prevent the media from sticking to the hot roll do make full contact with the hot roller The type 2 fuser unit assembly has a life of 150K Pressure roll Hot roll Hot roll Pressure roll Fuser lamp Non contact detac Non contact detac Hot roll Pressure roll Fuser lamp Full con...

Page 270: ... printer to the standard bin Sensor standard bin full The sensor standard bin full detects whether the standard bin is full by moving the actuator up and down Drive Main drive motor assembly The main drive motor is a DC motor that drives the print cartridge aligner MFP and fuser ...

Page 271: ...embly that transports the media into the standard bin or output option Electrical components and controller Switch printer front door interlock Redrive motor assembly Main drive motor assembly Main cooling fan System card assembly LVPS card assembly LVPS cooling fan Print cartridge cooling fan HVPS card assembly ...

Page 272: ...rint cartridge area to prevent excessive temperature increase Duplex cooling fan The Duplex cooling fan discharges air from the duplex drive motor area to prevent excessive temperature increase LVPS card assembly The LVPS card assembly generates low voltages 5V for logic circuits 5 V for laser diodes and 24V for cooling fans The LVPS is switchable and can be switched to work with 100V 110 and 220V...

Page 273: ... the heat roll surface temperature or printer conditions The fuser temperature control starts when the fuser ready in the system card assembly is turned on after a preset time period has passed from power on If a failure occurs the heater lamps are turned off the fuser ready is turned off and then the fuser temperature control is stopped Fuser lamp on off control The thermistor detects the heat ro...

Page 274: ...arm 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 Xerographic and print cartridge components ...

Page 275: ...f according to image information that is received from the host computer and software Through the use of a series of rotating and stationary mirrors within the Printhead the beam scans the negative charged drum surface Whenever the print controller sends a command to print a black pixel the laser switches on long enough to shine onto the drum at a single pixel point That point is now discharged an...

Page 276: ... the development roll to the surface of the drum The AC voltage agitates the toner on the development roll making toner transfer easier The development roll maintains a negative DC electrical potential Negative charged areas of the drum have a lower electrical potential or higher relative negative value than the development roll Discharged areas of the drum have a higher electrical potential or lo...

Page 277: ...es a positive charge to the back of the printing paper This positive charge transfers the negative charged toner image from the photoconductor drum to the top surface of the paper The toner image is now on the paper and the paper is now stuck to the photoconductor drum due to the relative electrical differences between the Developer Roll Metering Blade Toner HVPS DRUM VDC Drum Surface Voltage Drum...

Page 278: ...e electrical charge of the paper Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process The toner that the Cleaning Blade removes is collected inside the sealed PC Cartridge Sheet of paper HVPS VDC VDC DRUM Transfer roll Cleaning Blade Used Toner Charge roll DRUM ...

Page 279: ...ed toner patch and image on the photoconductor drum and outputs pulses when the central line of the patch image aligns with the central line of the detector The sensor outputs pulses at the timing the patch image passes the sensor Therefore observing changes of intervals at which pulses are output leads to toner density detection ...

Page 280: ...r CCD image sensor assembly This ADF employs a constant velocity transport system that scans images by feeding the document at a constant speed over the specified position scan position where the carriage of the scanner unit assembly is fixed Names and functions of components The sections below describe the functions of main components of the scanner Scanner unit assembly Sensor FB length APS 1 Se...

Page 281: ...the overview of the steps before document scanning and that of simplex and duplex document scanning modes Setting a document When a document is set on the document tray assembly and the lead edge is pushed into the tray until it stops the ADF document set actuator moves to place the sensor ADF document set in the unshielded unblocked state Then the machine recognizes that the document has been set...

Page 282: ...age is scanned the document sheet is fed and ejected by the ADF feed out roll assembly and ADF exit roll assembly that are driven by the ADF transport motor 5 When the trail edge of the first document sheet has passed through the sensor sheet through the feed of the second document sheet starts Duplex document For duplex document sheets feed is performed in the following sequence 1 The first docum...

Page 283: ...sor ADF width 3 Sensor ADF width 3 The document length in the fast scanning direction is detected by the combination of these three sensors detecting the position of the tray on which the document is set Sensor ADF document set A sensor that detects the presence or absence of a document on the ADF document tray ADF Document Set LED An LED that illuminates when a document is set on the ADF Document...

Page 284: ...scan is installed just down stream of the scanning surface and is used to for scanning timing operations Sensor ADF media exit The sensor ADF media exit is used to detect when scanned media has exited the ADF ADF feed motor assembly The feed motor assembly is a stepping motor that rotates the pick roll and feed roll in the reverse direction CCW direction and rotates the ADF transport roll assembly...

Page 285: ...perly pick the media Switch ADF closed interlock Sensor Media exit Sensor ADF lower door interlock Sensor ADF document set Sensor ADF front registration Sensor ADF rear registration Sensor ADF sheet through Sensor ADF top door interlock Sensor ADF media length Sensor ADF media width ADF pick solenoid ...

Page 286: ...city Input Tray HCIT tray assembly Rear media tray guide Media end guide Pick arm assembly Sensor media empty Sensor media low Media size actuator Sensor pass through HCF drawer assembly Sensor tray raised HP Tray lift drive motor ...

Page 287: ...sensing finger which then sets the switches of the controller card board The combination of ON OFF position of the three switches provides information of the media sizes to the engine Note Media size sensing through ON OFF switch combination Media size SW 1 SW 2 SW 3 Unknown OFF OFF OFF A4 OFF OFF ON Legal OFF ON OFF B5 OFF ON ON A5 ON OFF OFF Executive ON OFF ON Letter ON ON OFF Custom ON ON ON R...

Page 288: ...rd force at the pick roll through the pick arm gear train Sensor A B The photointerrupter sensors send signals to the engine the media level status is empty low or full An actuator flag triggers the sensor by blocking it Sensor pass thru A photointerrupter sensor with a built in flag that sends a signal to the engine where the media from the input tray passes This will trigger the pick arm to pick...

Page 289: ...c aids 3 77 Pick arm assembly Sensor media empty Sensor media low 250 sheet drawer assembly Sensor pass through Pick arm assembly Sensor media empty Sensor media low 550 sheet drawer assembly Sensor pass through ...

Page 290: ...components directly associated with the media path and transport PC cartridge Sensor input PC drum Standard bin full actuator and sensor standard bin full Diverter Sensor duplex input Sensor fuser output Sensor narrow media Pick arm assembly Sensor option pass through Models X651 X652 5535dn X654 and X656 paper path rolls and sensors ...

Page 291: ...ide guide of the media tray assembly to match the media size Rear media guide The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear The rear guide should come into contact with the media and hold it in position Side guide PC cartridge Sensor input PC drum Standard bin full actuator and sensor standard bin full Diverter Sensor duplex input Sen...

Page 292: ...n the pick rolls pick up media the remaining media decreases and the media out actuator will lower and interact with the sensor media low and sensor media empty to determine the amount of media remaining The pick arm assembly autocompensator is a paper pick device that generates its own normal force This force generation is inherent in the fundamental design of the pick arm If light media is used ...

Page 293: ...area of the sensor media empty The sensor light is transmitted When the sensing area is blocked media is present the signal is off Sensor media low This sensor detects by the actuator position whether media in the media tray assembly is low When the flag of the actuator blocks then unblocks the sensing area of the sensor media low the media level is determined to be low Tray 2 media tray assembly ...

Page 294: ... the main components of the duplex Sensor duplex input The sensor duplex wait detects whether media is remaining in the duplex Duplex drive motor assembly The duplex drive motor assembly transmits driving force to the two duplex media transport roll assemblies and the duplex media center transport roll assembly middle that feeds media Duplex drive motor assembly Sensor duplex input ...

Page 295: ...ll jammed paper from the paper path The following table lists the jams that can occur and the location of each jam 200 and 203 paper jams 1 Touch Status Supplies to identify the location of the jam 2 Lower the multipurpose feeder door Jam numbers Area 1 200 203 Printer 2 230 239 Duplex unit 3 240 245 Paper tray 4 250 Multipurpose feeder 5 260 Envelope feeder 6 270 279 Optional output bin 7 28x Sta...

Page 296: ...g Do not touch the photoconductor drum on the underside of the cartridge Use the cartridge handle whenever you are holding the cartridge 5 Place the print cartridge aside Warning Do not leave the cartridge exposed to light for extended periods Warning The jammed paper may be covered with unfused toner which can stain garments and skin 3 ...

Page 297: ...l the print cartridge 8 Close the front cover 9 Close the multipurpose feeder door 10 Touch Continue 202 paper jam Touch Status Supplies to identify the location of the jam If the paper is exiting the printer then pull the paper out and then touch Continue If the paper is not exiting the printer 1 Pull down the top rear door 2 Remove the jammed paper 3 Close the top rear door 4 Touch Continue 230 ...

Page 298: ...3 86 Service Manual 3 Pull down the bottom rear door 4 Push the tab down 5 Remove the jammed paper 6 Close the bottom rear door 7 Insert the standard tray 8 Touch Continue ...

Page 299: ...s to identify the location of the jam 2 Pull the standard tray out 3 Remove any jammed paper and then close the tray 4 Touch Continue 5 If the jam message remains then pull out any optional trays 6 Remove the jammed paper and then insert the trays 7 Touch Continue ...

Page 300: ...traighten the edges on a level surface 4 Load the paper into the multipurpose feeder 5 Slide the paper guide toward the inside of the tray until it lightly rests against the edge of the paper 6 Touch Continue 260 paper jam Touch Status Supplies to identify the location of the jam The envelope feeder feeds envelopes from the bottom of the stack the bottom envelope will be the one that is jammed 1 L...

Page 301: ...the envelopes 7 Load the envelopes in the envelope feeder 8 Adjust the paper guide 9 Lower the envelope weight 10 Touch Continue 270 279 paper jams To clear a jam in the high capacity output stacker or the 4 bin mailbox 1 Touch Status Supplies to identify the location of the jam 2 If the paper is exiting into a bin then pull the paper straight out and then touch Continue If not then continue with ...

Page 302: ...ice Manual 3 Pull the latch of the staple cartridge holder down and then pull the holder out of the printer 4 Use the metal tab to lift the staple guard and then remove any loose staples 5 Close the staple guard ...

Page 303: ...lace 7 Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place 8 Close the stapler door 290 294 paper jams 1 Remove all original documents from the ADF 2 Open the ADF cover and then remove any jammed paper 3 Close the ADF cover ...

Page 304: ...2 Service Manual 4 Open the scanner cover and then remove any jammed pages 5 Open the bottom ADF door and then remove any jammed pages 6 Close the bottom ADF door and scanner cover 7 Touch Restart Job 1 2 ...

Page 305: ...f negative or positive skew is present this will help with determining the correct adjustment to be made Acceptable ADF and flatbed scanner specifications Scan Flatbed LE TE left right edges 0 5 or 0 005mm mm ADF simplex and duplex LE TE left right edges 0 75 Copy Flatbed ADF simplex and duplex LE TE left right edges 0 75 ...

Page 306: ... adjustment via ADF document tray 2 Loosen the screws securing the ADF document tray on either side A ADF cover rear removal on page 4 65 1 Remove the ADF cover front and ADF cover rear Go to ADF cover front removal on page 4 64 and X654 and X656 on page 4 134 or Scanner cover left removal model X658 on page 4 135 1 Remove the scanner cover left Go to Scanner cover left removal models X651 X652 55...

Page 307: ... rotate the document tray clockwise as shown above 4 For positive skew rotate the document tray counterclockwise as shown above 5 After skew correction has been made tighten the document tray screws and reinstall the ADF front and rear covers ...

Page 308: ...3 96 Service Manual ADF skew adjustment Via duplex CCD assembly 1 Remove the ADF cover front Go to ADF cover front removal on page 4 64 ...

Page 309: ...urn of the adjustment screw yields 5 mm of skew correction The maximum adjustment is three turns for clockwise movement of the screw and four turns for counterclockwise movement 4 After skew has been corrected tighten the M4 screw above Assembly is reverse of the removal procedures Note If the bracket above is aligned with the alignment hole in the ADF frame the duplex CCD assembly is parallel wit...

Page 310: ...l when cut paper is being used to align the ADF skew during reworks Pallets of quality paper may be found with more than 2 mm of skew 1 Remove two consecutive pieces of paper from the ream 2 Flip one of the pages over in the direction shown below 1 2 Long Edge 1 2 ...

Page 311: ...Diagnostic aids 3 99 3 This shows the final position of the two pages 4 Tap the two pages on a flat surface until the bottom edge is aligned 1 ...

Page 312: ...ok closely at the top edge of the media to see if the sheets are aligned Square Media Top and sides are perfectly aligned The two pages do not align perfectly at the top or sides Media Not square use for ADF skew rework DO NOT ...

Page 313: ...properly aligned 3 Check the base printer skew and registration 4 Plug printer into the power source and power on in Diagnostics Mode hold down 3 and 6 during POR 5 Measure L1 L2 T1 T2 R1 R2 B1 and B2 data points as shown below 6 Determine the following calculations L2 L1 ___ R2 R1 ___ T2 T1 ___ B2 B1 ___ T1 L1 T2 R1 B2 R2 B1 L2 ...

Page 314: ...f the page Adjust as needed Skew Specification L2 L1 R2 R1 T2 T1 B2 B1 Letter 1 4 mm 1 4 mm 1 mm 1 mm A4 1 5 mm 1 5 mm Legal 1 8 mm 1 8 mm 8 If the printer does not meet the skew specifications adjust the reference edge as specified in Alignment assembly adjustment on page 4 3 or adjust the printhead as specified in Polygon printhead mechanical registration adjustment on page 4 2 as needed ...

Page 315: ... the flatbed 5 Make sure the autodocument guides are snug against the page 6 Plug printer into the power source and power on in Normal Printing Mode 7 Measure CopyL1 CopyL2 CopyT1 CopyT2 CopyR1 CopyR2 CopyB1 and CopyB2 data points as shown below 8 Measure from the edge of the paper to the outer edge of the thick black line 9 Determine the following calculations CopyL2 CopyL1 ___ CopyR2 CopyR1 ___ ...

Page 316: ...w Specification Measurement Specification Description CopyL2 CopyL1 2 0 mm Left Skew CopyR2 CopyR1 2 0 mm Right Skew CopyT2 CopyT1 1 5 mm Top Skew CopyB2 CopyB1 1 5 mm Bottom skew Copy Registration Specification Measurement Specification Description CopyT1 CopyB1 3 0 mm Vertical Registration CopyL1 CopyR1 4 0 mm Horizontal Registration 11 Adjust the skew as specified in Adjusting skew on page 3 93...

Page 317: ...pin connector a looped handle is attached to the top of the small yellow jumper that covers the 3 pin connector An administrator controls how a jumper reset affects a device by configuring the jumper related setting on the Security Web page Note Administrators can discourage tampering with the jumper by securing the entire RIP card cage of which the jumper is a part with a Kensington lock or to co...

Page 318: ... moved from its previous home position position A to the other position position B then it performs a jumper reset After performing the reset the device also relabels the other position position B as the home position now position A is the other location Note The admin s security settings are lost when the RIP card is replaced Secure settings are those that are configured under the Settings Securi...

Page 319: ... Top Margin x Bottom Margin x Left Margin x Right Margin x Skew x Cyan Top Margin x Cyan Left Margin xx Cyan Right Margin x Cyan Skew x Cyan Bow x Yellow Top Margin x Yellow Left Margin x Yellow Right Margin x Yellow Skew x Yellow Bow x Magenta Top Margin x Magenta Left Margin x Magenta Right Margin x Magent Skew x magenta Bow x Dup Top Margin x Paper Source Tray 1 Formatted Size xxxxxx Quick Test...

Page 320: ...tor Vertical page length accuracy 0 5mm drive motor Print Position Error Measured at any point in the printable area using core media papers Vertical process 0 7mm Horizontal magnification 0 7mm Duplex Skew Specification Side 1 2 Print Sequence Thru Printer 2nd 1st 16 lb to 24 lb 0 007 mm mm 0 005 mm mm All Other Papers 0 010 mm mm 0 005 mm mm Card Stock 0 007 mm mm 0 007 mm mm Labels Paper Dual W...

Page 321: ...city in your body to the machine Hold the ESD sensitive part by its edge connector shroud cover do not touch its pins If you are removing a pluggable module use the correct tool Do not place the ESD sensitive part on the machine cover or on a metal table if you need to put down the ESD sensitive part for any reason first put it into its special bag Machine covers and metal tables are electrical gr...

Page 322: ...055 0 FFN APS F191a 0 LF LBH P055 0 NF APS N179 0 LF LBH P055 0 AF LB E037 0 9 9 8 31M02 U5 0 Quick Test Device Information Printer Revision Levels Printer Margin Settings Page Cou nt Installed Memory Processor Speed 31 192 MB 467MHz Serial Number 0116413 TDS Calibration 00 14 FF 00 00 00 00 Engine ID 40 System Card ID 0004007E24A2 Top Margin 5 Bottom Margin 0 Left Margin Right Margin Dup Top Marg...

Page 323: ...ve the two screws holding the alignment assembly to the left side frame 3 Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from the printer It is not necessary to completely remove the screw 4 Install the new alignment assembly Turn the reference screw clockwise with a 7 mm nut driver or M3 Allen wrench until it touches the back of the reference plat...

Page 324: ... minimum gap between sheets of paper as they are fed through the printer This adjustment reduces the printer overall performance such as pages per minute but can help in reducing the amount of curl of some printed media thus improving media stacking in the output bin 1 Enter the Diagnostic Mode 2 Select Ep Setup from the Diagnostic Menu 3 Select Gap Adjust 4 The range of the GAP adjustment is 0 to...

Page 325: ...nching wires obstructing the paper path or restricting mechanical movement Note A wide variety of screws are used make note of their positions during service CAUTION Remove the power cord from the electrical outlet before you connect or disconnect any cable or electronic board or assembly CAUTION While performing service around the fuser assembly ensure the fuser area has cooled down ...

Page 326: ...assembly 2 Open the operator panel door assembly or the print cartridge door assembly 3 Detach the left side of the charge roll assembly from the machine 4 Detach the right side of the charge roll assembly from the machine 5 Remove the charge roll assembly Replacement Warning When replacing the charge roll assembly avoid touching the charge roll surface ...

Page 327: ... the harnesses B from the clamp 5 Disconnect the connection C from the duplex assembly Note When removing the duplex assembly the lower duplex drive belt D will become detached 6 Remove the duplex assembly Replacement Warning When replacing the duplex assembly ensure that the lower duplex drive belt D is properly reattached A D B C 1 Remove the duplex drive motor assembly See Duplex drive motor as...

Page 328: ... 3 Disconnect the connector B from the duplex cooling fan 4 Remove the duplex cooling fan Replacement Warning When replacing the duplex cooling fan ensure that it is installed as shown in the picture A B X656 on page 4 122 1 Remove the side cover right See Side cover right removal models X651 X652 5535dn X654 and ...

Page 329: ...uplex drive belt B will become detached 4 Remove the band C from the duplex drive motor assembly 5 Remove the cover from the duplex drive motor assembly 6 Disconnect the connection D to the duplex drive motor assembly A B C 1 Remove the fuser access door See Fuser access door assembly removal on page 4 12 2 Remove the cover assembly rear lower See Cover assembly rear lower X654 X656 and X658 on pa...

Page 330: ...removal 1 Remove the media tray 2 Gently place the printer on its left or right side 3 Disconnect the connection A from the duplex input sensor assembly 4 Remove the two screws B securing the duplex input sensor assembly to the machine 5 Remove the duplex input sensor assembly Duplex guide assembly front removal 1 Remove the media tray 2 Gently place the printer on its left or right side 3 Detach ...

Page 331: ...ion 4 11 4 Detach the front right duplex guide spring B from the duplex guide assembly front 5 Fully open the duplex guide assembly front 90 and detach it from the machine 6 Remove the duplex guide assembly front A B ...

Page 332: ...ow 4 Remove the media turn guide Replacement Warning When replacing the media turn guide ensure that it is properly installed or jamming will occur Fuser access door assembly removal A 1 Remove the MPF tray door assembly See Operator panel assembly removal model X658 on 1 Remove the door assembly rear See Door assembly rear removal on page 4 36 on page 4 97 page 4 109 or MPF tray door assembly rem...

Page 333: ...two tabs A on the fuser access door assembly and detach it from the machine 3 Swing the fuser access door assembly away from the machine 4 Unsnap the fuser access door assembly from the machine 5 Remove the fuser access door assembly A A ...

Page 334: ... shield in the direction of the arrow 4 Remove the metal shield 5 Remove the two screws B securing the fuser cooling fan to the machine 6 Remove the fuser cooling fan A X656 on page 4 123 or Side cover left removal model X658 on page 4 123 1 Remove the side cover left See Side cover left removal models X651 X652 5535dn X654 and ...

Page 335: ...rive release linkage from the machine 4 Remove the fuser drive release linkage Fuser unit assembly removal 3 Open the fuser access door 4 Press the two buttons A on the fuser unit assembly to release it from the machine B C 1 Remove the system card assembly See System card assembly removal on page 4 50 1 Remove the fuser wiper cover assembly See Fuser wiper cover assembly removal on page 4 16 2 Re...

Page 336: ...e 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 Press the button A securing the fuser wiper cover assembly to the machine 2 Remove the fuser wiper cover assembly B A A ...

Page 337: ...e that the two high voltage connections C are properly replaced Inner deflector removal Note The MPF lift plate assembly can be detached and allowed to hang by the harness The connection to the MPF lower deflector assembly does not need to be disconnected C A B X656 on page 4 122 or Side cover right removal model X658 on page 4 121 1 Remove the side cover right See Side cover right removal models ...

Page 338: ...he machine 3 Remove the inner deflector Replacement Warning When replacing the inner deflector ensure that it is properly installed or jamming will occur Option drive shaft removal 1 Gently place the printer on its left or right side 2 Using pliers gently pull the option drive shaft from the machine A ...

Page 339: ...Repair information 4 19 3 Remove the spring Replacement Warning When replacing the option drive shaft ensure that the plastic hook A is not damaged or the option drive shaft will not remain secured A ...

Page 340: ...operly 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 Replacement Warning When replacing the main drive motor assembly ensure that all gears and drive shafts are properly aligned or damage will occur A B 1 Remove the system...

Page 341: ...he metal cover A the adjuster screw C or jamming will occur See Alignment assembly adjustment on page 4 3 4 Remove the inner deflector See Inner deflector removal on page 4 17 5 Remove the MPF pick solenoid assembly See MPF pick solenoid assembly removal on page 4 26 1 Remove the side cover left See Side cover left removal models X651 X652 5535dn X654 and X656 on page 4 123 or Side cover left remo...

Page 342: ...w C can be accessed through the hole D in the system card 7 Completely loosen the adjuster screw C securing the alignment assembly to the machine 8 Remove the alignment assembly Replacement Warning When replacing the alignment assembly ensure that the media skew is properly B D C adjusted using the adjuster screw C or jamming will occur Go to Alignment assembly adjustment on page 4 3 ...

Page 343: ...ecuring the media out actuator to the unit 3 Remove the media out actuator Media support removal 1 Gently detach the two bosses A of the media support from the machine 2 Remove the media support A A A 1 Remove the pick arm assembly See Pick arm assembly removal on page 4 29 ...

Page 344: ...should be removed from the media tray cabinet 4 Remove the tray roller catch assembly from the machine MPF cam gear removal 2 Release the hook A securing the gear to the unit 3 Remove the MPF cam gear A 2 Remove the HVPS card assembly See HVPS card assembly removal on page 4 17 1 Remove the alignment assembly See Alignment assembly removal on page 4 21 ...

Page 345: ... the lever C is held down when reinstalling the MPF lift plate assembly or damage will occur Replacement Warning When replacing the MPF lift plate assembly ensure that the MPF pick solenoid assembly does not become damaged MPF media out actuator removal 2 Gently unsnap the MPF media out actuator from the machine 3 Remove the media out actuator A B C 1 Remove the media turn guide See Media turn gui...

Page 346: ...Note The MPF lift plate assembly can be detached and allowed to hang by the harness The connection does not need to be disconnected 3 Remove the six screws A securing the metal cover to the machine B A A 1 Remove the media turn guide See Media turn guide removal on page 4 12 1 Remove the MPF lift plate assembly See MPF lift plate assembly removal on page 4 25 X656 on page 4 123 or Side cover left ...

Page 347: ...Repair information 4 27 4 Remove the metal cover 5 Remove the screw B securing the MPF pick solenoid assembly to the machine 6 Remove the MPF pick solenoid assembly B C ...

Page 348: ...4 28 Service Manual 7 Disconnect the connection C from the MPF pick solenoid assembly C ...

Page 349: ...n 4 29 Pick arm assembly removal 1 Remove the media tray from the machine 2 Place the machine on the left or right side 3 Remove the spring A 4 Remove the two E clips B securing the pick arm assembly to the machine B A ...

Page 350: ...embly 8 Remove the three connections E from the pick arm assembly 9 Remove the wiring harness F from the pick arm assembly 10 Remove the pick arm assembly Replacement Warning When replacing the pick arm assembly ensure that the connections are properly replaced C E F D re routed Replacement Warning When replacing the pick arm assembly ensure that the harnesses are properly ...

Page 351: ...Print cartridge cooling fan removal 2 Remove the screw A securing the print cartridge cooling fan to the machine 3 Remove the print cartridge cooling fan 4 Disconnect the connection B from the print cartridge cooling fan Replacement Warning When replacing the print cartridge cooling fan ensure that it is installed as shown in the picture A A A B X656 on page 4 122 or Side cover right removal model...

Page 352: ...ht printer cartridge hold down assembly 2 Remove the screw A securing the print cartridge clamp assembly to the machine 3 Remove the print cartridge clamp assembly A X656 on page 4 106 or Laser cover removal model X658 on page 4 104 1 Remove the laser cover See Laser cover removal models X651 X652 5535dn X654 and ...

Page 353: ...ase the two hooks A securing the print cartridge ID connector assembly to the machine 4 Remove the print cartridge ID connector assembly 5 Disconnect the connection B from the print cartridge ID connector assembly A B 2 Remove the main drive motor assembly See Main drive motor assembly removal on page 4 20 ...

Page 354: ...curing the metal cover to the machine 3 Remove the metal cover 4 Disconnect the connections B from the printhead assembly A A B print quality issues will occur See Polygon printhead mechanical registration adjustment on page 4 2 1 Remove the laser cover See Laser cover removal models X651 X652 5535dn X654 and X656 on page 4 106 or Laser cover removal model X658 on page 4 104 ...

Page 355: ...replacing the printhead assembly ensure that the printhead skew is properly Connection access cover rear removal 1 Gently detach the two hinges A of the connection access cover rear from the machine 2 Remove the connection access cover rear C A adjusted or print quality issues will occur See Polygon printhead mechanical registration adjustment on page 4 2 ...

Page 356: ... door assembly rear at a 45 angle as shown in the picture 4 Remove the door assembly rear Duplex guide assembly rear removal 2 Remove the media tray 3 Gently place the printer on its left or right side 4 Remove the two screws A securing the two retainers B to the machine 5 Remove the two retainers B 1 Remove the cover assembly rear lower See Cover assembly rear lower X654 X656 and X658 on page 4 3...

Page 357: ...mation 4 37 6 Detach the rear duplex guide spring C 7 Remove the duplex guide assembly rear 8 Remove the screw D securing the rear duplex guide handle to the assembly 9 Remove the duplex guide assembly rear A B C D ...

Page 358: ...e cover assembly rear lower to the machine 3 Remove the cover assembly rear lower Redrive motor assembly removal 2 Remove the six screws A securing the metal cover to the machine A A 1 Remove the laser cover See Laser cover removal models X651 X652 5535dn X654 and X656 on page 4 106 or Laser cover removal model X658 on page 4 104 ...

Page 359: ...Repair information 4 39 3 Remove the metal cover 4 Disconnect the connection B from the redrive motor assembly 5 Disconnect the connection C from the sensor standard media bin full B ...

Page 360: ...hooks D securing the output option interface cable assembly to the machine 7 Detach the output option cable assembly 8 Remove the two screws E securing the redrive motor assembly to the machine 9 Remove the redrive motor assembly D C E ...

Page 361: ...Sensor media empty removal 2 Release the hooks A securing the sensor media empty to the assembly 3 Remove the sensor media empty Sensor toner empty removal A A A 1 Remove the duplex input sensor assembly See Duplex input sensor assembly removal on page 4 10 1 Remove the pick arm assembly Go to Pick arm assembly removal on page 4 29 1 Remove the pick arm assembly See Pick arm assembly removal on pa...

Page 362: ...the sensor toner empty Sensor input removal 2 Release the hooks A securing the sensor input to the machine 3 Remove the sensor input 4 Disconnect the connection B from the sensor input Sensor shield assembly removal A 1 Remove the inner deflector See Inner deflector removal on page 4 17 1 Remove the inner deflector See Inner deflector removal on page 4 17 ...

Page 363: ...e sensor shield assembly from the machine 3 Remove the sensor shield assembly Replacement Warning When replacing the sensor shield assembly ensure that the spring A is properly aligned and the sensor shield assembly opens and closes properly A ...

Page 364: ...embly from the machine 4 Remove the standard bin actuator assembly Sensor standard bin exit actuator removal 1 Release the hooks A securing the sensor standard bin exit actuator to the assembly 2 Remove the sensor standard bin exit actuator 1 Remove the laser cover See Laser cover removal models X651 X652 5535dn X654 and X656 on page 4 106 or Laser cover removal model X658 on page 4 104 ...

Page 365: ...oner density Switch media size assembly removal 2 Remove the six screws A securing the metal cover to the machine 3 Remove the metal cover 4 Remove the media tray A 1 Remove the sensor shield assembly See Sensor shield assembly removal on page 4 42 X656 on page 4 123 or Side cover left removal model X658 on page 4 123 1 Remove the side cover left See Side cover left removal models X651 X652 5535dn...

Page 366: ...ace the machine on the left of right side 6 Release the two hooks B securing the switch media size assembly to the machine 7 Remove the switch media size assembly 8 Disconnect the connection C from the switch media size assembly B C ...

Page 367: ...ct the connector A from the LVPS card assembly 4 Remove the two screws B from the LVPS card assembly 5 Gently pull the LVPS card assembly from the machine B B A 1 Remove the door assembly rear See Door assembly rear removal on page 4 36 and X656 on page 4 122 or Side cover right removal model X658 on page 4 121 2 Remove the side cover right See Side cover right removal models X651 X652 5535dn X654...

Page 368: ... the LVPS card assembly ensure that all connections are replaced Replacement Warning When replacing the LVPS card assembly ensure that the connector pins D properly engage the system card Replacement Warning When replacing the LVPS card assembly ensure that the voltage selection switch E is set to the proper setting or damage will occur C D E ...

Page 369: ...Repair information 4 49 Access door removal 1 Open the access door 2 Gently detach the two hinges A of the access door from the machine 3 Remove the access door A ...

Page 370: ...hod of troubleshooting as long as the machine is booted into diagnostic mode or is operating in diagnostic mode Once a component has been installed in a machine and powered up into user mode it cannot be used in another machine It must be returned to the manufacturer 2 Remove the six screws A securing the metal shield to the machine 3 Slide the metal shield in the direction of the arrow CAUTION Th...

Page 371: ...and harnesses do not become damaged 5 Disconnect all connections from the system card assembly Note There are two fine thread screws and four course thread screws securing the system card assembly to the machine ensure that these screws are properly reinstalled 6 Remove the six screws B securing the system card assembly to the machine ...

Page 372: ...bly 8 Remove any remaining screws securing the system card assembly to the metal box 9 Remove the system card assembly Replacement Warning Ensure that all ground wires are properly replaced Replacement Warning When replacing the system card assembly ensure that the LVPS assembly connections C are properly aligned and inserted into the system card assembly or damage will occur C B ...

Page 373: ...e hard drive to the rear of the machine 3 Remove the system card metal plate 4 Gently detatch the hard drive from the system card 5 Disconnect the connector from the system card A Hard drive connector 1 Remove the side cover left See Side cover left removal model X658 on page 4 123 ...

Page 374: ...g bracket 5 Remove the two screws A securing the hard drive cooling fan to the fan mounting bracket 6 Remove the hard drive cooling fan 7 Disconnect the connector from the system card Replacement Warning When replacing the duplex cooling fan ensure that it is installed as shown in the picture A Connector 1 Remove the side cover left See Side cover left removal model X658 on page 4 123 ...

Page 375: ...3 Loosen the two screws A securing the fax card assembly to the rear of the machine 4 Gently detatch the fax card assembly from the machine 5 Disconnection the connection from the system card A Fax connector 1 Remove the side cover left See Side cover left removal model X658 on page 4 123 ...

Page 376: ...Open the operator panel door assembly 2 Remove the print cartridge 3 Gently unsnap the transfer roll assembly from the machine 4 Remove the transfer roll assembly Replacement Warning When replacing the transfer roll assembly do not touch the foam surface ...

Page 377: ...w E 9 Remove the ground wire F 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 Remove the transfer roll assembly See Transfer roll assembly removal on page 4 56 2 Remove the inner deflector See Inner deflector removal on page 4 17 2 Remove the inne...

Page 378: ...4 58 Service Manual 3 Remove the screw A securing the transfer roll bracket assembly right to the machine 4 Remove the transfer roll bracket assembly right A ...

Page 379: ...ve the transfer deflector 4 Remove the screw A securing the ground wire to the transfer deflector 5 Remove the ground wire Replacement Warning When replacing the transfer deflector ensure that the ground wire is properly replaced A 1 Remove the transfer roll assembly See Transfer roll assembly removal on page 4 56 ...

Page 380: ...he two screws A securing the redrive assembly to the machine 4 Press the two tabs B to release the redrive assembly to the machine While pressing the two tabs B pull the redrive assembly from the machine A B B 1 Remove the door assembly rear See Door assembly rear removal on page 4 36 ...

Page 381: ...61 ADF feed pick roll assembly removal 1 Lift the ADF top door assembly 2 Slide the ADF pick roll assembly to the front 3 Lift the rear of the ADF pick roll assembly 4 Remove the ADF pick roll assembly Rear Right Front Left ...

Page 382: ...rator roll removal 1 Lift the ADF top door assembly 3 Remove the access cover 4 Press tab A and slide the separator roll off the shaft A 2 Remove the ADF feed pick roll assembly See ADF feed pick roll assembly removal on page 4 61 ...

Page 383: ...rque limiter assembly removal 1 Lift the ADF top door assembly 3 Remove the access cover 4 Press tab A and slide the separator roll off the shaft A 2 Remove the ADF feed pick roll assembly See ADF feed pick roll assembly removal on page 4 61 ...

Page 384: ... front and remove ADF cover front removal 1 Lift the ADF top door assembly 2 Remove two screws A from the top of the front cover assembly 3 Remove one screw B from the bottom of the ADF cover front 4 Release the bottom tabs C on the ADF cover front 5 Remove the ADF cover C B A ...

Page 385: ...l screws A from the top of the ADF document tray assembly 4 Slide the ADF document tray assembly to the right 5 Disconnect the ADF paper length width sensors cable 6 Remove the ADF document tray assembly B A 1 Remove the ADF cover front See ADF cover front removal on page 4 64 2 Remove the ADF cover rear See ADF cover rear removal on page 4 65 Replacement note You must adjust skew after reinstalli...

Page 386: ...own on the spring clips A on the left and right sides 5 Remove the ADF left door links B 6 Unscrew the two hinge pins C on the left and right side C C B A 1 Remove the ADF cover front See ADF cover front removal on page 4 64 2 Remove the ADF cover rear See ADF cover rear removal on page 4 65 ...

Page 387: ...DF top door assembly ADF controller card removal 2 Disconnect all cables attached to the controller card 3 Remove the four screws A securing the ADF controller card 4 Remove the ADF controller card D 1 Remove the ADF cover rear See ADF cover rear removal on page 4 65 ...

Page 388: ...ttom door by pressing the green tab A on the underside of the front of the ADF unit assembly 3 Remove the screw B securing the ground wire to the ADF unit assembly 4 Remove the two screws C securing the bottom door hinge plate 5 Remove the hinge plate and pull the ADF lower door assembly and remove A C B 1 Remove the ADF platen cushion See ADF platen cushion removal on page 4 68 ...

Page 389: ... lower door assembly 3 Remove four screws A from the ADF duplex CCD scan glass assembly 4 Pull up and release the two snaps B securing the ADF duplex CCD scan glass assembly 5 Remove the ADF duplex CCD scan glass assembly B A 1 Remove the ADF platen cushion See ADF platen cushion removal on page 4 68 ...

Page 390: ...plug the product before you begin or use caution if the product must receive power in order to perform the task 2 Disconnect the CCD harness from the top of the ADF unit assembly 3 Remove the skew adjustment locking screw A the skew adjustment screw B and the spring A B 1 Remove the ADF duplex CCD scan glass assembly See ADF duplex CCD scan glass assembly removal X654 X656 and X658 on page 4 69 ...

Page 391: ...ws D from the underside of the ADF unit assembly securing the ADF duplex CCD assembly to the ADF 6 Carefully remove the ADF duplex CCD assembly from the underside of the ADF unit assembly D C Replacement note You must adjust skew after reinstalling the ADF duplex CCD assembly Go to Adjusting skew on page 3 93 ...

Page 392: ...DF pinch roll assembly removal 2 Remove the two screws A on either side of the ADF pinch roll assembly 3 Remove the ADF pinch roll assembly A 1 Remove the ADF top door assembly See ADF top door assembly removal on page 4 66 ...

Page 393: ...a flat blade screwdriver unfasten the hook securing the separator guide to the turn guide Note Upon reassembly reattach the hook by pressing with your fingers until it snaps into place A 1 Remove the ADF pinch roll assembly See ADF pinch roll assembly removal on page 4 72 2 Remove the ADF separator torque limiter assembly See ADF separator torque limiter assembly removal on page 4 63 ...

Page 394: ...6 Remove the ADF turn guide ADF media pinch pad assembly removal A B 1 Remove the ADF duplex CCD assembly See ADF duplex CCD assembly removal X654 X656 and X658 on page 4 70 2 Remove the ADF pinch roll assembly See ADF pinch roll assembly removal on page 4 72 3 Remove the ADF turn guide See ADF turn guide removal on page 4 73 ...

Page 395: ...Repair information 4 75 4 Remove the four screws A securing the ADF media pinch pad assembly 5 Remove the ADF media pinch pad assembly A ...

Page 396: ...dia exit fan bracket assembly 6 Remove screw B from the ground strap 7 Remove the sensor ADF media exit fan bracket assembly Note Remove the fan filter cover assembly from the used sensor ADF media exit fan bracket assembly and install on the new sensor ADF media exit fan bracket assembly Replacement note Be sure to reinstall the ground strap 1 Remove the ADF cover front See ADF cover front remova...

Page 397: ...rive motor bracket to the right loosening the transport belt 7 Remove ADF transport drive motor bracket assembly with cable ADF feed drive motor assembly removal 2 Unfasten and remove all wires from the ADF feed drive motor assembly 3 Disconnect the ADF feed motor harness from the feed motor 4 Remove the E clip A securing one end of the ADF feed pick roll feed shaft to the ADF feed drive motor ass...

Page 398: ...anual 5 Remove the bushing from the pick roll feed shaft 6 Remove the six screws B securing the ADF feed motor assembly to the ADF unit assembly 7 Remove the ADF feed motor assembly to include two belts and cable A B ...

Page 399: ...ree screws C securing the ADF pick roll position cam assembly bracket 6 Remove the ADF pick roll position cam assembly bracket 7 Remove it from the shaft 8 Slide the shaft and ADF pick roll position cam assembly out of the ADF frame A B B C 1 Remove the ADF cover front See ADF cover front removal on page 4 64 2 Remove the ADF feed pick roll assembly See ADF feed pick roll assembly removal on page ...

Page 400: ...lock removal 3 Disconnect the sensor harness from sensor 4 Remove the sensor ADF top door interlock bracket screw A 5 Remove the bracket with the sensor ADF top door interlock 6 Detach the sensor ADF top door interlock from the bracket by squeezing the clip B and removing the sensor A B 1 Remove the ADF cover front See ADF cover front removal on page 4 64 1 Remove the ADF cover rear assembly See A...

Page 401: ...nsor ADF lower door interlock Sensor ADF 2nd scan removal 2 Remove the sensor ADF 2nd scan harness from the sensor 3 Remove the sensor from the pinch pad mounting bracket assembly by squeezing the tabs A on the sensor A A A A 1 Remove the ADF cover front See ADF cover front removal on page 4 64 2 Remove the ADF platen cushion See ADF platen cushion removal on page 4 68 1 Remove the ADF media pinch...

Page 402: ...st scan 4 Remove the sensor ADF first scan harness Sensor ADF sheet through removal 2 Remove the screw A securing the sensor ADF sheet through to its bracket 3 Remove the sensor ADF sheet through 4 Remove the sensor ADF sheet through harness A A 1 Remove the ADF turn guide See ADF turn guide removal on page 4 73 1 Remove the ADF turn guide See ADF turn guide removal on page 4 73 ...

Page 403: ...ator guide to the ADF frame 3 Remove the sensor ADF document set harness 4 Remove the two screws B securing the sensor ADF document set bracket to the ADF frame 5 Remove the sensor ADF document set and bracket A 1 Remove the ADF document tray assembly See ADF document tray assembly removal on page 4 65 ...

Page 404: ...erlock removal 2 Open the ADF unit assembly 3 Remove the ADF closed interlock harness from the switch 4 Using a prying tool press the tabs A on either side of the switch and pull it down through the bottom of the ADF unit assembly B C A A 1 Remove the ADF cover rear assembly See ADF cover rear removal on page 4 65 ...

Page 405: ...t the CCD harness and ground strap from behind the rear scanner cover 5 Open the ADF A 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 Replacement note You must adjust skew after reinstalling the ADF unit assembly Go to Adjusting skew on page 3 93 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 2 Remove the scanner support cover left See Sc...

Page 406: ...cement note You must adjust skew after reinstalling the ADF unit assembly Go to Adjusting skew on page 3 93 2 Remove the ADF feed motor bracket assembly with cable See ADF feed drive motor assembly removal on page 4 77 and X656 on page 4 85 or ADF unit assembly removal model X658 on page 4 85 1 Remove the ADF unit assembly See ADF unit assembly removal models X651 X652 5535dn X654 ...

Page 407: ...nge to the ADF unit assembly 4 Remove the ADF right hinge A A 2 Remove the ADF cover rear assembly See ADF cover rear removal on page 4 65 ADF right hinge removal X654 and X656 on page 4 85 or ADF unit assembly removal model X658 on page 4 85 1 Remove the ADF unit assembly See ADF unit assembly removal models X651 X652 5535dn ...

Page 408: ...lide the cover left rear corner up and out Cover right rear corner removal model X658 2 Open the rear door A 1 Remove the scanner support cover left rear See Scanner support cover left rear removal model X658 on page 4 150 1 Remove the scanner support cover right side rear See Scanner support cover right rear removal model X658 on page 4 127 ...

Page 409: ...e the cover right rear corner Sensor standard bin exit actuator assembly removal 1 Open the upper rear door 2 Remove the fuser access panel A X654 and X656 on page 4 103 or Redrive assembly removal model X658 on page 4 103 3 Remove the redrive assembly See Redrive assembly removal models X651 X652 5535dn ...

Page 410: ...ensor ADF media exit bracket assembly removal X651 3 Open the ADF top door assembly 4 Disconnect the ground strap the fan CN12 harness and the media exit sensor CN9 harness 5 Remove the two screws A on the front and rear of the sensor ADF media exit fan bracket assembly 6 Remove the laser cover See Laser cover removal model X658 on page 4 104 1 Remove the ADF cover front See ADF cover front remova...

Page 411: ... Scanner CCD assembly removal CAUTION When you see this symbol there is a danger from hazardous voltage in the area of the product where you are working Unplug the product before you begin or use caution if the product must receive power in order to perform the task 2 Loosen the screw A on the carriage belt tensioner 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover a...

Page 412: ...B from the flatbed frame by lifting the left end of the shaft up and remove through the left side 6 Lift the scanner CCD assembly from front shaft 7 Rotate the scanner CCD assembly upside down and carefully remove the ribbon cable 8 Remove the scanner CCD assembly A B Replacement note You must adjust skew after reinstalling the scanner CCD assembly Go to Adjusting skew on page 3 93 ...

Page 413: ...ed frame 3 Remove the scanner reference LED cable assembly 4 Remove the wire harness from the scanner reference LED cable assembly A 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal assembly removal model X658 on page 4 139 models X651 X652 5535dn X654 and X656 on page 4 140 or Scanner platen glass cover ...

Page 414: ...o diagnostic mode or is operating in diagnostic mode Once a component has been installed in a machine and powered up into user mode it cannot be used in another machine It must be returned to the manufacturer 2 Remove the scanner controller card cage cover 3 Remove all cables 4 Remove the two plastic screws A and screw B securing the ground strap to the left side of the scanner unit assembly 6 Rem...

Page 415: ...Repair information 4 95 7 Remove the screw D securing the ground strap to the frame of the scanner unit assembly 8 Carefully slide the scanner unit assembly to the front and lift up C D ...

Page 416: ...nents can be used as a method of troubleshooting as long as the machine is booted into diagnostic mode or is operating in diagnostic mode Once a component has been installed in a machine and powered up into user mode it cannot be used in another machine It must be returned to the manufacturer 3 Remove the scanner controller card cage cover 4 Disconnect the CCD and ribbon cable harnesses 5 Remove t...

Page 417: ...der tabs out of the slots in the manual feed tray 3 Rotate the manual feeder vertical and pull straight up to remove the feeder 4 Slide the MPF input tray towards the front and remove two clips A securing the MPF door hinges A MPF tray door assembly removal models X651 X652 5535dn X654 and X656 ...

Page 418: ...4 98 Service Manual 5 Bow the door slightly to remove the right side hinge pin 6 Slide the door assembly to the left until the door clears all the pins B ...

Page 419: ... to the left and remove MPF tray door assembly removal model X658 1 Open the MPF tray door assembly 3 Remove the two retaining clips A from the hinges on the MPF tray door 2 Remove the MPF media guide assembly See MPF media guide assembly removal model X658 on page 4 108 ...

Page 420: ...on link 6 Pull the right tension link from the hinge 7 Slide the MPF tray door assembly to the left until all the bosses clear the hinges 8 Angle the left side of the MPF tray door assembly down and slide it back to the right until the door is clear of the right hinge 9 Remove the MPF tray door assembly A B ...

Page 421: ...assembly rear 1 Remove the door assembly rear See Door assembly rear removal on page 4 124 Note If you do not have a short screwdriver remove the scanner unit assembly See Scanner unit Output cover assembly removal model X651 X652 5535dn X654 and X656 assembly removal models X651 X652 5535dn X654 and X656 on page 4 94 ...

Page 422: ...three screws A securing the output cover assembly to the machine 3 Remove the output cover assembly Output cover assembly removal model X658 1 Open the door assembly rear 2 Lift the right side of the fuser exit access panel and remove A ...

Page 423: ... and right clips B 5 Remove the redrive assembly 2 Remove the two screws A securing the redrive assembly to the machine 3 Remove the fuser wiper cover B A 1 Remove the fuser access assembly See Fuser access assembly removal on page 4 101 1 Remove the fuser access assembly See Fuser access assembly removal on page 4 101 Redrive assembly removal models X651 X652 5535dn X654 and X656 ...

Page 424: ...ontroller card See Scanner controller card assembly removal model X658 on page 4 129 4 Remove the redrive assembly See Redrive assembly removal model X658 on page 4 103 1 Remove the ADF unit assembly See ADF unit assembly removal model X658 on page 4 85 2 Remove the scanner unit assembly See Scanner unit assembly removal model X658 on page 4 96 ...

Page 425: ...ve screws A on the left securing the laser cover 6 Remove the four screws on the right B securing the laser cover A B 7 Remove the sensor ADF media exit fan bracket assembly See Sensor standard bin exit actuator assembly removal on page 4 89 ...

Page 426: ...troller card See Scanner controller card assembly removal models X651 Laser cover removal models X651 X652 5535dn X654 and X656 2 Remove the scanner unit assembly See Scanner unit assembly removal models X651 X652 5535dn X654 and X656 on page 4 94 X654 and X656 on page 4 85 1 Remove the ADF unit assembly See ADF unit assembly removal models X651 X652 5535dn model X658 on page 4 129 X652 5535dn X65...

Page 427: ...en the front operator panel door 10 Remove the laser cover B 8 Remove the sensor ADF media exit bracket assembly See Sensor ADF media exit bracket assembly removal X651 on page 4 90 and X656 on page 4 103 7 Remove the redrive assembly See Redrive assembly removal models X651 X652 5535dn X654 ...

Page 428: ...guide assembly removal model X658 1 Open the MPF feeder door 2 Remove the two tabs A from the slots to disconnect the MPF media guide assembly A A 1 Remove the scanner from the scanner support platform See Scanner support platform removal Standard output bin LED assembly removal models X651 X652 5535dn X654 and X656 models X651 X652 5535dn X654 and X656 on page 4 141 ...

Page 429: ...ing the assembly vertical and lift up Operator panel assembly removal model X658 1 Pull the operator panel door assembly forward and remove 2 Remove the two screws A securing the USB port to the operator panel door assembly 3 Remove the three screws B securing the operator panel assembly bottom to the scanner frame ...

Page 430: ...ecuring the operator panel assembly 6 Slide the operator panel assembly to the left 7 Rotate the operator panel assembly upside down and remove the three screws E 8 Separate the lower panel from the upper panel 9 Disconnect the operator panel and cave light harnesses 10 Remove the operator panel assembly C D E ...

Page 431: ...n over the operator panel assembly 3 Remove the 3 screws A from the back of the operator panel assembly 4 Separate the lower panel B from the upper panel and turn it over A B 1 Remove the operator panel assembly See Operator panel assembly removal model X658 on page 4 109 ...

Page 432: ...4 112 Service Manual 5 Remove the four screws C securing the the card reader bracket to the lower panel 6 Remove the bracket D 7 Remove the card reader assembly E C D E ...

Page 433: ...Repair information 4 113 8 Disconnect the cable F from the card reader F ...

Page 434: ...nel assembly 3 Remove the 3 screws A from the back of the operator panel assembly 4 Separate the lower panel B from the upper panel 5 Turn the upper panel to face the inner part A B 1 Remove the operator panel assembly See Operator panel assembly removal model X658 on page 4 109 ...

Page 435: ...springs A on both sides 3 Remove the print cartridge cover springs B on both sides 4 Remove the E clips C on both sides securing the links to the hinges and remove the links D C Operator panel door assembly removal models X651 X652 5535dn X654 and X656 1 Remove the laser cover See Laser cover removal models X651 X652 5535dn X654 and X656 on page 4 106 ...

Page 436: ...4 116 Service Manual 5 Remove the pins D on both sides securing the links C A B D ...

Page 437: ...roller cage cover to the cage An X658 model is represented in the graphic below however the card cage cover removal procedure is similar for all models 7 Remove the printer controller card cage cover 8 Disconnect the USB cable and the cover closed interlock switch harness E E ...

Page 438: ...4 118 Service Manual 9 Lift the operator panel door assembly out of the machine ...

Page 439: ...ver assembly 2 Remove the ten screws A securing the operator panel cover latch assembly to the operator panel cover assembly 3 Remove the operator panel cover latch assembly Operator panel cover latch assembly removal models X651 X652 5535dn X654 and X656 ...

Page 440: ...vice Manual Print cartridge cover assembly removal model X658 1 Open the print cartridge cover assembly 2 Remove the two screws A securing the print cartridge cover assembly 3 Remove the cartridge access door A ...

Page 441: ...t removal model X658 2 Open the front door 3 Open the cartridge access door 4 Remove the screw A and pull the side cover right up and out to remove 1 Remove the cover left rear corner See Cover left rear corner removal model X658 on page 4 88 ...

Page 442: ...he front 7 Remove the screw B from the rear 8 Firmly grasp the cover from the top and pull out to remove 1 Remove the door assembly rear assembly See Door assembly rear removal on page 4 124 2 Remove the cover rear lower See Cover rear lower removal on page 4 125 Side cover right removal models X651 X652 5535dn X654 and X656 ...

Page 443: ...e paper tray 4 Open the MPF door 5 Open the cartridge access door A 1 Remove the cover left rear corner See Cover left rear corner removal model X658 on page 4 88 1 Remove the door assembly rear See Door assembly rear removal on page 4 124 2 Remove the rear lower door See Cover rear lower removal on page 4 125 Side cover left removal models X651 X652 5535dn X654 and X656 ...

Page 444: ... left by pulling out the tabs on the top and bottom and by pulling the cover out of its rear hinges Door assembly rear removal 1 Open the door assembly rear 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 A ...

Page 445: ... 4 125 4 Remove the door assembly rear Cover rear lower removal 2 Remove the two screws A on each side of the cover 3 Open the cover rear lower 1 Remove the door assembly rear See Door assembly rear removal on page 4 124 ...

Page 446: ...4 126 Service Manual 4 Remove the remaining two screws B 5 Lift and remove the cover rear lower A B A ...

Page 447: ...r information 4 127 Scanner support cover right rear removal model X658 1 Remove the four screws A securing the scanner support cover right rear to the machine 2 Remove the scanner support cover right rear A ...

Page 448: ... Remove the four screws A securing the scanner support inner cover right to the machine 3 Pull the bottom out and remove the scanner support inner cover right A 1 Remove the scanner support cover right rear See Scanner support cover right rear removal model X658 on page 4 127 ...

Page 449: ... support cover right Scanner controller card assembly removal model X658 1 Remove the scanner support inner cover right See Scanner support inner cover right removal model X658 on page 4 128 1 Remove the scanner support cover left See Scanner support cover left removal model X658 on page 4 152 2 Remove the side cover left See Side cover left removal model X658 on page 4 123 ...

Page 450: ...4 130 Service Manual 3 Remove eight screws A securing the scanner controller cage cover to the cage 4 Remove the scanner controller card cage cover 5 Disconnect all the harnesses and ribbon cables A A ...

Page 451: ...Repair information 4 131 6 Remove the seven screws B securing the card to the cage 7 Remove the scanner controller card ...

Page 452: ...troller cage cover to the cage 3 Remove the scanner controller card cage cover A A Scanner controller card assembly removal models X651 X652 5535dn X654 and X656 X656 on page 4 123 1 Remove the side cover left See Side cover left removal models X651 X652 5535dn X654 and ...

Page 453: ...on cables 5 Remove the seven screws B securing the card to the cage 6 Remove the scanner controller card Scanner cover rear removal 1 Remove the four screws A securing the scanner cover rear to the scanner 2 Pull out from the bottom and remove the scanner cover rear ...

Page 454: ...crew B securing the scanner cover left to the scanner assembly 3 Slide the scanner cover left to the rear and remove B A 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 Scanner cover left removal models X651 X652 5535dn X654 and X656 ...

Page 455: ... left removal model X658 2 Remove the metal screw A securing the scanner cover left to the scanner assembly 3 Slide the scanner cover left to the rear and remove A 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 ...

Page 456: ...securing the scanner cover right to the machine 3 Slide the scanner cover right to the rear and remove Replacement note Always replace the scanner cover front before replacing the scanner cover right 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 1 Remove the scanner cover rear See Scanner cover right removal model X658 on page 4 136 Scanner cover right removal models...

Page 457: ...e scanner cover front 3 Pull and remove the scanner cover front Scanner cover front removal model X658 2 Remove screw A A 1 Remove the scanner cover right See Scanner cover right removal model X658 on page 4 136 Scanner cover front removal models X651 X652 5535dn X654 and X656 ...

Page 458: ...4 138 Service Manual 3 Slide the scanner cover front to the right and remove Replacement note Always replace the scanner cover front before replacing the scanner cover right ...

Page 459: ...e six screws A securing the scanner platen glass cover to the assembly 6 Lift and remove the scanner platen glass cover assembly 1 Remove the ADF unit assembly See ADF unit assembly removal model X658 on page 4 85 2 Remove the scanner cover left See Scanner cover left removal model X658 on page 4 135 4 Remove the scanner cover front See Scanner cover front removal model X658 on page 4 137 3 Remove...

Page 460: ...ly removal models X651 X652 5535dn X654 and X656 X654 and X656 on page 4 85 X654 and X656 on page 4 137 X654 and X656 on page 4 136 1 Remove the ADF unit assembly See ADF unit assembly removal models X651 X652 5535dn 2 Remove the scanner cover front See Scanner cover front removal models X651 X652 5535dn 3 Remove the scanner cover right See Scanner cover right removal models X651 X652 5535dn ...

Page 461: ...latbed frame 4 Remove the last screw C under the plastic cover securing the scanner support platform to the scanner 5 Remove the torroid from the ribbon cable A 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal Scanner support platform removal models X651 X652 5535dn X654 and X656 models X651 X652 5535dn X654 and X656 on page 4 140 ...

Page 462: ...surface which the scanner is placed on 7 Push the flatbed toward the rear of the cover 8 Lift and remove the scanner support platform 9 If the scanner support platform needs to be removed from the printer remove the four mounting screws as outlined in the scanner unit assembly removal See Scanner unit assembly removal models X651 X652 5535dn X654 and X656 on page 4 94 ...

Page 463: ...r pulley 3 Remove the two screws A securing the carriage belt tensioner assembly to the flatbed scanner frame 4 Remove the carriage belt tensioner assembly 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal models X651 X652 5535dn X654 and X656 on page 4 140 or Scanner platen glass cover assembly removal model X658 on page 4 139 ...

Page 464: ...ng washer C and belt from the motor output shaft 6 Remove the carriage drive motor harness D 7 Remove the rear CCD scanner shaft E from the flatbed frame by lifting the left end of the shaft up and remove through the left side A 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal assembly removal model X658 on page 4 139 models X651 X652 5535dn X654 and...

Page 465: ...l slack in the carriage belt and retighten screw A 4 Remove the clip B and retaining washer C from carriage drive motor assembly with cable 5 Remove the carriage belt from the carriage belt tension assembly and the drive motor assembly F F A 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal assembly removal model X658 on page 4 139 models X651 X652 55...

Page 466: ...4 146 Service Manual 6 Slide the carriage belt out of the rear side of the CCD carriage assembly ...

Page 467: ...ssembly 4 Remove the two screws C securing the exposure lamp card from the underside of the CCD assembly and lift the card from the CCD assembly 5 Disconnect the scanner lamp wiring harness from the exposure lamp card 1 Remove the scanner CCD assembly or the ADF duplex CCD assembly See Scanner CCD assembly removal on page 4 91 or ADF duplex CCD assembly removal X654 X656 and X658 on page 4 70 ...

Page 468: ...up on the rear end and pulling the lamp out of the grommet Scanner interface card assembly removal 2 Remove the wire harnesses from the scanner interface card 3 Remove the four screws A securing the scanner interface card to the flatbed frame 4 Remove the scanner controller card 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 ...

Page 469: ...erface card connector CN5 assembly 3 Remove the two screws A securing the scanner cooling fan to the flatbed frame 4 Remove the scanner cooling fan while carefully routing the cable out from the flatbed frame assembly 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal models X651 X652 5535dn X654 and X656 on page 4 140 or Scanner platen glass cover ass...

Page 470: ...model X658 2 Remove the two inner screws A and two screws B on the rear face securing the scanner support cover left rear to the machine 3 Remove the scanner support cover left rear A B 1 Remove the scanner cover rear See Scanner cover rear removal on page 4 133 ...

Page 471: ...n 4 151 Scanner support cover left front removal model X658 1 Open the front door assembly 2 Remove the two screws A on the scanner support cover left front to the machine 3 Remove the scanner support cover left front A ...

Page 472: ...ve the scanner support cover left rear See Scanner support cover left rear removal model X658 on page 4 150 2 Remove the scanner support cover left front See Scanner support cover left front removal model X658 on page 4 151 1 Remove the scanner support cover left rear See Scanner support cover left rear removal model X658 on page 4 150 2 Remove the scanner support cover left front See Scanner supp...

Page 473: ...platen glass length cable cover 4 Rotate the sensor platen glass length assembly upside down and remove the harnesses from each individual sensor 5 Remove the sensor platen glass length assembly 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal models X651 X652 5535dn X654 and X656 on page 4 140 or Scanner platen glass cover assembly removal model X65...

Page 474: ...y with bracket LVPS cooling fan 2 Remove the four screws A securing the LVPS cooling fan 3 Disconnect the connection from the LVPS cooling fan A A 1 Remove the scanner platen glass cover assembly See Scanner platen glass cover assembly removal 1 Remove the LVPS card assembly See LVPS card assembly removal on page 4 47 models X651 X652 5535dn X654 and X656 on page 4 140 or Scanner platen glass cove...

Page 475: ...Repair information 4 155 4 Remove the LVPS cooling fan ...

Page 476: ...4 156 Service Manual Option removals High capacity input tray ...

Page 477: ... assembly removal 1 Open the HCIT media tray assembly until it reaches a stop 2 Press the latch A down on the left side of the HCIT tray slide and press the latch B up on the right side of the HCIT tray slide 3 Slide the HCIT media tray assembly out of the drawer B A ...

Page 478: ...Manual High capacity input tray HCIT tray cover front removal 1 Open the HCIT media tray assembly until it reaches a stop 2 Remove the six screws A securing the HCIT tray cover front to the HCIT media tray assembly A ...

Page 479: ...Repair information 4 159 3 Remove the HCIT tray cover front A ...

Page 480: ... Manual High capacity input tray HCIT cover rear removal Note Carefully remove the base machine from the HCIT tray assembly before proceeding 1 Remove the four screws A securing the HCIT cover rear to the drawer A A ...

Page 481: ...Repair information 4 161 2 Remove the HCIT cover rear ...

Page 482: ...ng the HCIT cover right to the drawer 3 Use a screwdriver to gently pry up on the tabs B A B A Note Before removing the HCIT right cover first remove the right side anti tip latch assembly See High capacity input tray HCIT anti tip latch assembly removal on page 4 165 1 Remove the High capacity input tray HCIT cover rear See High capacity input tray HCIT cover rear removal on page 4 160 ...

Page 483: ...Repair information 4 163 4 Remove the HCIT cover right A ...

Page 484: ...crews A securing the HCIT cover left to the drawer 3 Use a screwdriver to gently pry up on the tabs B A A B Note Before removing the HCIT cover left first remove the left side anti tip latch assembly See High capacity input tray HCIT anti tip latch assembly removal on page 4 165 1 Remove the HCIT cover rear See High capacity input tray HCIT cover rear removal on page 4 160 ...

Page 485: ...tch assembly removal Note Carefully remove the base machine from the HCIT tray assembly before proceeding The left and right anti tip latch assemblies are the same and only one is in a package The instructions below are for removing the left latch removing the right latch has similar instructions ...

Page 486: ...4 166 Service Manual Note The left side anti tip assembly will come off when removing the HCIT cover left 1 Remove the HCIT cover left See High capacity input tray HCIT cover left removal on page 4 164 ...

Page 487: ... slide to the frame of the drawer 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 A 1 Remove the HCIT media tray assembly See High capacity input tray HCIT media tray assembly removal on page 4 157 1 Remove the HCIT cover right See High capacity input tray HCIT c...

Page 488: ...able connector from the HCIT controller card assembly Note Remove the cable from the restraint and observe the routing for reinstallation 4 Remove the eight screws A securing the HCIT tray lift drive motor assembly 5 Remove the HCIT tray lift drive motor assembly A A ...

Page 489: ...ard assembly removal Note Carefully remove the base machine from the HCIT tray assembly before proceeding 2 Disconnect all connectors from the HCIT controller card assembly 1 Remove the HCIT cover left See High capacity input tray HCIT cover left removal on page 4 164 ...

Page 490: ...media size actuator assembly removal Note Carefully remove the base machine from the HCIT tray assembly before proceeding 2 Disconnect the two springs A from the frame 3 Slide the cam size sensing plate B through the access hole in the rear side frame A A B 1 Remove the HCIT controller card assembly See High capacity input tray HCIT controller card assembly removal on page 4 169 ...

Page 491: ...nap loose the actuator switch C and remove 5 Remove the four screws D securing the media size actuator E and the card mount option F to the frame 6 Remove the screw securing the media size actuator to the card mount option C D F E ...

Page 492: ... tray assembly before proceeding 2 Disconnect the sensor HCIT tray raised HP from the HCIT controller card assembly Note Remove the cable from the restraints and observe the routing for reinstallation 3 Remove the screw A securing the sensor to the upper rear frame 4 Release the hooks A securing the sensor to the rear frame 1 Remove the HCIT cover left See High capacity input tray HCIT cover left ...

Page 493: ...HCIT tray raised HP Sensor HCIT pass through with cable removal Note Carefully remove the base machine from the HCIT tray assembly before proceeding A 1 Remove the HCIT cover left See High capacity input tray HCIT cover left removal on page 4 164 ...

Page 494: ...h from the HCIT controller card assembly Note Remove the cable restraint and observe the routing for reinstallation 3 Release the hooks A securing the sensor HCIT pass through to the machine 4 Remove the sensor HCIT pass through with cable from the top plate A A ...

Page 495: ...mbly before proceeding 2 Remove the HCIT pick arm bracket assembly cable connectors from the HCIT controller card assembly Note Remove the cable from the restraint and observe the routing for reinstallation 3 Remove the pick arm lift spring from the drawer 1 Remove the HCIT cover left See High capacity input tray HCIT cover left removal on page 4 164 ...

Page 496: ...4 176 Service Manual 4 Remove the five screws A securing the HCIT pick arm bracket assembly 5 Remove the HCIT pick arm bracket assembly from the drawer by slightly lifting and removing it A ...

Page 497: ...The instructions below are for removing the left latch removing the right latch has similar instructions 2 Remove the E clip A and the washer B with a prying tool securing the HCIT tray closed latch with spring to the left frame 3 Remove the HCIT tray closed latch with spring A B 1 Remove the HCIT tray assembly See High capacity input tray HCIT media tray assembly removal on page 4 157 ...

Page 498: ...edia tray assembly removal Remove the 250 sheet media tray assembly from the 250 sheet option drawer assembly 250 sheet option drawer assembly removal Remove the 250 sheet media tray assembly from the 250 sheet option drawer assembly ...

Page 499: ...ay assembly before proceeding 1 Disconnect the two 250 sheet pick arm bracket assembly cable connectors from the 250 sheet controller card assembly 2 Detach the pick arm spring from the drawer 3 Remove the three screws A securing the 250 sheet pick arm bracket assembly to the drawer 4 Remove the 250 sheet pick arm bracket assembly A ...

Page 500: ...oceeding The left and right anti tip latch assemblies are the same and only one is in a package The instructions below are for removing the left latch but removing the right latch is similar 2 Turn the drawer over so that you are looking at the bottom of the anti tip latch assembly Using a flathead screwdriver unsnap the two latches A securing the anti tip latch assembly to the drawer 3 Remove the...

Page 501: ...y Sensor pass through with cable removal Note Carefully remove the base machine from the input option tray assembly before proceeding 2 Release the hooks securing the sensor pass through to the drawer 3 Remove the sensor pass through from the drawer 1 Remove the 250 sheet pick arm bracket assembly See 250 sheet pick arm bracket assembly removal on page 4 179 1 Remove the 250 sheet pick arm bracket...

Page 502: ...4 182 Service Manual 4 Remove the four screws A securing the 250 sheet frame assembly to the drawer 5 Remove the 250 sheet frame assembly ...

Page 503: ...Repair information 4 183 6 Disconnect the sensor pass through cable connector from the 250 sheet controller card 7 Remove the sensor pass through with cable ...

Page 504: ...securing the sensor pass through to the drawer 3 Remove the sensor pass through from the drawer 4 Remove the four screws A securing the 250 sheet frame assembly to the drawer 1 Remove the 250 sheet pick arm bracket assembly See 250 sheet pick arm bracket assembly removal on page 4 179 ...

Page 505: ...eet frame assembly 6 Disconnect the three connectors from the 250 sheet controller card assembly 7 Remove the three screws B securing the 250 sheet controller card assembly to the 250 sheet frame 8 Remove the 250 sheet controller card assembly A ...

Page 506: ...achine from the input option tray assembly before proceeding 2 Remove the screw A securing the media size actuator to the 250 sheet frame 3 Remove the media size actuator A 1 Remove the 250 sheet controller card assembly Go to 250 sheet controller card assembly removal on page 4 184 ...

Page 507: ...ing 2 Release the hooks securing the sensor pass through to the drawer 3 Remove the sensor pass through from the drawer 4 Remove the four screws A securing the 250 sheet frame assembly to the drawer 5 Remove the 250 sheet frame assembly 1 Remove the 250 sheet pick arm bracket assembly See 250 sheet pick arm bracket assembly removal on page 4 179 ...

Page 508: ...dia tray catch spring 7 Release the media tray catch spring Tray roller catch assembly removal Note Carefully remove the base machine from the input option tray assembly before proceeding 1 Remove the media tray catch spring See Media tray catch spring removal on page 4 187 ...

Page 509: ...Repair information 4 189 2 Remove the tray roller catch assembly from the drawer ...

Page 510: ...4 190 Service Manual 550 sheet option tray assembly ...

Page 511: ... media tray assembly removal Remove the 550 sheet media tray assembly from the 550 sheet option drawer assembly 550 sheet option drawer assembly removal Remove the 550 sheet media tray assembly from the 550 sheet option drawer assembly ...

Page 512: ...the 550 sheet controller card assembly 3 Detach the 550 sheet bellcrank recoil spring B from the drawer 4 Remove the four screws C securing the 550 sheet pick arm bracket assembly to the drawer 5 Remove the 550 sheet pick arm bracket assembly A 1 Remove the 550 sheet media tray assembly See 550 sheet media tray assembly removal on page 4 191 ...

Page 513: ...edia out actuator with spring to the 550 sheet pick arm bracket assembly 3 Detach the spring B from the media out actuator A B 1 Remove the 550 sheet pick arm bracket assembly See 550 sheet pick arm bracket assembly removal on page 4 192 1 Remove the 550 sheet pick arm bracket assembly See 550 sheet pick arm bracket assembly removal on page 4 192 Media out actuator removal models T652 and T654 ...

Page 514: ...latch is similar 2 Turn the drawer over so that you are looking at the bottom of the anti tip assembly Using a flathead screwdriver unsnap the two hooks A securing the anti tip latch to the drawer Note The hooks might break when detaching the anti tip latch assembly from the drawer 3 Remove the anti tip latch assembly A 1 Remove the 550 sheet media tray assembly See 550 sheet media tray assembly r...

Page 515: ...2 Release the hooks securing the sensor pass through to the drawer 3 Remove the sensor pass through from the drawer 4 Remove the four screws A securing the 550 sheet frame assembly to the drawer A 1 Remove the 550 sheet pick arm bracket assembly See 550 sheet pick arm bracket assembly removal on page 4 192 ...

Page 516: ...4 196 Service Manual 5 Remove the 550 sheet frame assembly ...

Page 517: ...assembly Lower interface cable assembly removal 2 Disconnect the lower interface cable connector A from the 550 sheet controller card 3 Pinch the options auto connect B to separate the lower interface cable assembly from the 550 sheet frame 4 Remove the lower interface cable assembly B A B A 1 Remove the 550 sheet frame assembly See 550 sheet frame assembly removal on page 4 195 1 Remove the 550 s...

Page 518: ...ard 3 Remove the sensor pass through with cable 550 sheet controller card assembly removal 2 Disconnect the three connectors from the 550 sheet controller card assembly 1 Remove the 550 sheet frame assembly See 550 sheet frame assembly removal on page 4 195 1 Remove the 550 sheet frame assembly See 550 sheet frame assembly removal on page 4 195 ...

Page 519: ...Repair information 4 199 3 Remove the three screws A securing the 550 sheet controller card assembly to the 550 sheet frame 4 Remove the 550 sheet controller card assembly A ...

Page 520: ...tuator removal 2 Remove the screw A securing the media size actuator to the 550 sheet frame 3 Remove the media size actuator A 1 Remove the 550 sheet controller card assembly See 550 sheet controller card assembly removal on page 4 198 ...

Page 521: ... A on the cap and detach it from the 550 sheet frame 3 Pull the drive roll gear B the shaft with spring C and the bevel out through the opening 4 Remove the 550 sheet option drive shaft with spring A A B C A 1 Remove the 550 sheet frame assembly See 550 sheet frame assembly removal on page 4 195 ...

Page 522: ...h spring 3 Release the media tray catch spring Media tray roller catch assembly removal 2 Remove the tray roller catch assembly from the drawer 1 Remove the 550 sheet frame assembly See 550 sheet frame assembly removal on page 4 195 1 Remove the media tray catch spring See Media tray catch spring removal on page 4 202 ...

Page 523: ...g the door to the right 3 Once the left hinge has been disengaged pull the right hinge out 4 Remove the rear door assembly MFP stapler assembly right cover removal 1 Remove the two screws A on the inside of the exit bin compartment securing the right cover 2 Pull out on the front side of the right cover to disengage the tabs 3 Remove the right cover A ...

Page 524: ...ompartment securing the left cover 2 Pull out on the front side of the left cover to disengage the tabs 3 Remove the left cover MFP stapler assembly top cover removal A 1 Remove the left and right cover See MFP stapler assembly left cover removal on page 4 204 and MFP stapler assembly right cover removal on page 4 203 ...

Page 525: ...the top cover 3 Pull up and toward the front to remove the top cover MFP stapler assembly handle cover removal A 1 Remove the left and right cover See MFP stapler assembly left cover removal on page 4 204 and MFP stapler assembly right cover removal on page 4 203 ...

Page 526: ...emove the two screws A on each side of the 3 Lift up and to the rear to remove the cover MFP stapler assembly LED sensor cover removal 1 Remove the screw A securing the LED sensor cover to the underside of the output bin A A A ...

Page 527: ... 2 Remove the standard output bin LED See MFP stapler assembly standard output bin LED and LED clear lens removal on page 4 208 3 Remove the sensor finisher media bin present See MFP stapler assembly sensor finisher media bin present removal on page 4 208 ...

Page 528: ...r cover 3 Remove the harness connected to the media bin present sensor 4 Remove the sensor finisher bin media present MFP stapler assembly standard output bin LED and LED clear lens removal A 1 Remove the LED sensor cover See MFP stapler assembly LED sensor cover removal on page 4 206 1 Remove the LED sensor cover See MFP stapler assembly LED sensor cover removal on page 4 206 ...

Page 529: ... the LED and disconnect the harness 4 Remove the LED clear lens MFP stapler assembly tamper drive belt removal 2 Pull the belt out the tamper belt holder and remove the belt from the pulley A 1 Remove the tamper recoil spring See MFP stapler assembly tamper drive belt removal on page 4 209 ...

Page 530: ...he two screws A securing the tamper drive motor assembly to the tamper frame 5 Remove the tamper drive motor assembly MFP stapler assembly media stack flap and media stack flap actuator removal 2 Release the locking tab and slide the media stack flap actuator to the right and remove A 1 Remove the top cover See MFP stapler assembly top cover removal on page 4 204 1 Remove the handle cover See MFP ...

Page 531: ...Repair information 4 211 ...

Page 532: ... removal 2 Remove the four cable harnesses attached to the stapler unit assembly 3 Remove the three screws A securing the stapler unit assembly 4 Remove the stapler unit assembly A 1 Remove the right cover See MFP stapler assembly right cover removal on page 4 203 ...

Page 533: ...assembly 4 Remove the stapler stacker controller card assembly MFP stapler assembly paddle drive motor assembly removal 2 Disconnect the paddle motor harness from the controller card 3 Remove the cable from the harness clip A 1 Remove the left left cover See MFP stapler assembly left cover removal on page 4 204 1 Remove the left left cover See MFP stapler assembly left cover removal on page 4 204 ...

Page 534: ...4 214 Service Manual 4 Remove the two screws A securing the two paddle drive motor assemblies 5 Remove the paddle drive motor assembly A ...

Page 535: ...ur fingers pinch tab A securing the sensor media stack and remove MFP stapler assembly sensor paddle HP removal 2 Disconnect the harness to the sensor paddle home position A 1 Remove the top cover See MFP stapler assembly top cover removal on page 4 204 1 Remove the left cover See MFP stapler assembly left cover removal on page 4 204 ...

Page 536: ...stapler assembly sensor stapler access door interlock removal 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 A A 1 Remove the right cover See MFP stapler assembly right cover removal on page 4 203 ...

Page 537: ...ng your fingers pinch the tabs A securing the staple finisher sensor tamper HP left and right and remove MFP stapler assembly sensor bin full send removal A 1 Remove the top cover See MFP stapler assembly top cover removal on page 4 204 1 Remove the stapler stacker controller card assembly See Stapler stacker controller card assembly removal on page 4 213 ...

Page 538: ...n full send 3 Disconnect the harness and remove MFP stapler assembly sensor bin full receive removal 2 Remove the two screws A securing the sensor bin full receive 3 Disconnect the harness and remove A A 1 Remove the right cover See MFP stapler assembly right cover removal on page 4 203 ...

Page 539: ...e pliers carefully grip the sensor and pull it out and disconnect the harness Replacement Notes Using needlenose pliers place the rear most tab in the sensor bracket first Then push on the rear face of the sensor until the other two tabs snap into place A 1 Remove the stapler unit assembly from the See MFP stapler assembly stapler unit assembly removal on page 4 212 ...

Page 540: ...s to the sensor deflector HP 3 Release the tabs A securing the sensor to the unit 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 A 1 Remove the left cover See MFP stapler assembly left cover removal on page 4 204 ...

Page 541: ...3 Using your finger pull up on the top surface of the left cover while simultaneously pulling out and remove 4 bin mailbox assembly controller card assembly removal 2 Disconnect all harnesses from the controller card Note Label each deflector gate solenoid cable for correct replacement upon installation A 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal ...

Page 542: ...roller card to the 4 bin mailbox assembly and remove 4 bin mailbox assembly sensor media bin full removal 2 Disconnect the harness to the sensor media bin full 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal on page 4 221 ...

Page 543: ...nner cover 4 Release the tabs securing the sensor deflector gate HP and remove the sensor from the 4 bin mailbox assembly 5 Disconnect the harness from the sensor deflector gate HP 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal on page 4 221 2 Remove the 4 bin mailbox assembly rear door assembly See 4 bin mailbox assembly rear door assembly removal on ...

Page 544: ... Manual 4 bin mailbox assembly rear door assembly removal 1 Open the rear door 2 Gently spread each side of the 4 bin mailbox assembly until the rear door hinge is free to be removed 3 Remove the rear door assembly ...

Page 545: ...the right cover securing cover in place 3 Using your fingers pull up on the top of the right cover and pull out simultaneously to remove 4 bin mailbox assembly LED card assembly removal 2 Disconnect the 3 wire harnesses attached to the LED card assembly A A 1 Remove the 4 bin mailbox assembly right cover See 4 bin mailbox assembly right cover removal on page 4 225 ...

Page 546: ... card assembly 4 bin mailbox assembly top cover removal 3 Remove the four screws A on each side of the top cover securing it to the 4 bin mailbox assembly A A 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal on page 4 221 2 Remove the right cover See 4 bin mailbox assembly right cover removal on page 4 225 ...

Page 547: ...he 4 bin mailbox assembly 3 Carefully unroute the deflector gate solenoid cables from the cable clips under the top cover 4 Disconnect the appropriate deflector gate solenoid cable from the controller card 5 Pull the deflector gate solenoid and harness from the 4 bin mailbox assembly A A 1 Remove the 4 bin mailbox assembly top cover See 4 bin mailbox assembly top cover removal on page 4 226 ...

Page 548: ...e transport solenoid cable from the controller card 4 Remove the screw A securing the transport solenoid to the 4 bin mailbox assembly 5 Remove the transport solenoid and pull the cable through the left side frame A 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal on page 4 221 ...

Page 549: ...n mailbox assembly spring removal 2 Using a spring hook or needlenose pliers remove the spring off the hooks 1 Remove the 4 bin mailbox assembly rear door assembly See 4 bin mailbox assembly rear door assembly removal on page 4 224 ...

Page 550: ...er 4 Grasp the deflector gate and pull it out of its socket on each side Carefully remove the diverter from the machine 1 Remove the 4 bin mailbox assembly rear door assembly See 4 bin mailbox assembly rear door assembly removal on page 4 224 3 Remove the 4 bin mailbox assembly spring See 4 bin mailbox assembly spring removal on page 4 229 ...

Page 551: ... mailbox assembly deflector gate bin 4 removal 2 Grasp the 4th bin deflector gate and pull out on either side 1 Remove the 4 bin mailbox assembly rear door assembly See 4 bin mailbox assembly rear door assembly removal on page 4 224 ...

Page 552: ...ox empty 1 Open the rear door 2 Lift the deflector gate above the sensor pass through and using a flat blade screwdriver release the tabs securing the sensor pass through to the 4 bin mailbox assembly 4 Disconnect the sensor pass through harness from the controller board 3 Remove the 4 bin mailbox left cover See 4 bin mailbox assembly left cover removal on page 4 221 ...

Page 553: ...box empty 1 Open the rear door 2 Lift the deflector gate above the sensor mailbox empty and using a flat blade screwdriver release the tabs securing the sensor mailbox empty to the 4 bin mailbox assembly 4 Disconnect the sensor mailbox empty harness from the controller board 3 Remove the 4 bin mailbox left cover See 4 bin mailbox assembly left cover removal on page 4 221 ...

Page 554: ...box assembly standard output bin LED removal 1 Remove the three screws A on the underside of bin 1 securing the output bin LED bracket 2 Pull the output bin LED bracket out from the underside of bin 1 and disconnect the LED harness A ...

Page 555: ...Repair information 4 235 3 Remove the two screws B securing the output bin LED to the bracket and remove the output bin LED B ...

Page 556: ...n full actuator removal 2 Pry the front hinge of the media bin full actuator towards the rear until the front boss is released from its socket 1 Remove the 4 bin mailbox standard output bin LED See 4 bin mailbox assembly sensor mailbox empty removal on page 4 233 1 Remove the 4 bin mailbox assembly left cover See 4 bin mailbox assembly left cover removal on page 4 221 ...

Page 557: ...ge out of the slot by pushing the door to the right 3 Once the left hinge has been disengaged pull the right hinge out 4 Remove the offset stacker rear door assembly Offset stacker right cover removal 1 Remove the two screws A on the inside of the exit bin compartment securing the right cover 2 Pull out on the front side of the right cover to disengage the tabs 3 Remove the offset stacker right co...

Page 558: ...mpartment securing the left cover 2 Pull out on the front side of the left cover to disengage the tabs 3 Remove the offset stacker left cover Offset stacker top cover removal A 1 Remove the left and right cover See Offset stacker left cover removal on page 4 238 and Offset stacker right cover removal on page 4 237 ...

Page 559: ...f the top cover 3 Pull up and toward the front to remove the offset stacker top cover Offset stacker handle cover removal A 1 Remove the left and right cover See Offset stacker left cover removal on page 4 238 and Offset stacker right cover removal on page 4 237 ...

Page 560: ... the two screws A on each side of the offset stacker 3 Lift up and to the rear to remove the cover Offset stacker LED sensor cover removal 1 Remove the screw A securing the LED sensor cover to the underside of the output bin A A A ...

Page 561: ...2 Remove the offset stacker standard output bin LED See Offset stacker standard output bin LED and LED clear lens removal on page 4 242 3 Remove the sensor finisher media bin present See Offset stacker sensor finisher media bin present removal on page 4 242 ...

Page 562: ... the harness connected to the media bin present sensor 4 Remove the offset stacker sensor finisher bin media present Offset stacker standard output bin LED and LED clear lens removal A 1 Remove the offset stacker LED sensor cover See Offset stacker LED sensor cover removal on page 4 240 1 Remove the offset stacker LED sensor cover See Offset stacker LED sensor cover removal on page 4 240 ...

Page 563: ...the LED and disconnect the harness 4 Remove the LED clear lens Offset stacker tamper drive belt removal 2 Pull the belt out the tamper belt holder and remove the belt from the pulley A 1 Remove the offset stacker tamper recoil spring See Offset stacker tamper drive belt removal on page 4 243 ...

Page 564: ...rews A securing the tamper drive motor assembly to the tamper frame 5 Remove the tamper drive motor assembly Offset stacker media stack flap and media stack flap actuator removal 2 Release the locking tab and slide the media stack flap actuator to the right and remove A 1 Remove the offset stacker top cover See Offset stacker top cover removal on page 4 238 1 Remove the offset stacker handle cover...

Page 565: ...Repair information 4 245 ...

Page 566: ...r card assembly 4 Remove the stapler stacker controller card assembly Offset stacker paddle drive motor assembly removal 2 Disconnect the paddle motor harness from the controller card 3 Remove the cable from the harness clip A 1 Remove the left left cover See Offset stacker left cover removal on page 4 238 1 Remove the left left cover See Offset stacker left cover removal on page 4 238 ...

Page 567: ...the two paddle drive motor assemblies 5 Remove the paddle drive motor assembly Offset stacker sensor media stack removal 2 Disconnect the harness to the sensor media stack A 1 Remove the offset stacker top cover See Offset stacker top cover removal on page 4 238 ...

Page 568: ...e Offset stacker sensor paddle HP removal 2 Disconnect the harness to the offset stacker sensor paddle home position 3 Using your fingers pinch tab A securing the offset stacker sensor paddle home position and remove A A 1 Remove the offset stacker left cover See Offset stacker left cover removal on page 4 238 ...

Page 569: ... Using your fingers pinch the tabs securing the staple finisher sensor tamper HP left and right and remove Offset stacker sensor bin full send removal A 1 Remove the offset stacker top cover See Offset stacker top cover removal on page 4 238 1 Remove the stapler stacker controller card assembly See Stapler stacker controller card assembly removal on page 4 246 ...

Page 570: ...full send 3 Disconnect the harness and remove Offset stacker sensor bin full receive removal 2 Remove the two screws A securing the sensor bin full receive 3 Disconnect the harness and remove A A 1 Remove the offset stacker right cover See Offset stacker right cover removal on page 4 237 ...

Page 571: ... sensor deflector HP 3 Release the tabs securing the sensor to the offset stacker 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 1 Remove the offset stacker left cover See Offset stacker left cover removal on page 4 238 ...

Page 572: ...4 252 Service Manual ...

Page 573: ...F closed interlock Sensor Media exit Sensor ADF lower door interlock Sensor ADF document set Sensor ADF front registration Sensor ADF sheet through Sensor ADF top door interlock Sensor ADF media length ADF pick solenoid Sensors ADF Sensor ADF rear registration Sensor ADF media width ...

Page 574: ...5 2 Service Manual ...

Page 575: ...ubricants may chemically attack polycarbonate parts Use IBM no 10 oil P N 1280443 Approved equivalents Mobil DTE27 Shell Tellus 100 Fuchs Renolin MR30 IBM no 23 grease Approved equivalent Shell Darina 1 and grease P N 99A0394 to lubricate appropriate areas Use Nyogel type 774 to lubricate the Fuser Drive Assembly and Nyogel 744 to lubricate the ITU and Cartridge Drive assemblies Individual mainten...

Page 576: ...er cord from the wall outlet and disconnect all cables to the printer before proceeding 2 Remove paper from the standard exit bin 3 Dampen a clean lint free cloth with water Warning Do not use household cleaners or detergents as they may damage the finish of the printer 4 Wipe only the outside of the printer making sure to include the standard exit bin Warning Using a damp cloth to clean the inter...

Page 577: ... water 2 Open the scanner cover 3 Wipe the scanner glass until it is clean and dry 4 Wipe the white underside of the scanner cover until it is clean and dry 5 Open the bottom ADF door 6 Wipe the ADF scanner glass under the ADF door 7 Close the bottom ADF door 8 Wipe the scanner glass flatbed and backing material by moving the cloth or paper towel from side to side 1 2 Cleaning the scanner glass ...

Page 578: ...ing 1 800 505 5327 Order kit s KS SP12 or KS SP50 or the LCD screen as cosmetic damage to those assemblies may result Note Dell recommends the use of Klear Screen cleaner for the scanner glass LCD screen and operator Warning Dell does not recommend the use of any alcohol based solution on the operator panel buttons ...

Page 579: ...ion used in the parts catalog Asm index Part number Units mach OR Units option Units FRU Description The following legend is used in the parts catalog Asm index Identifies the assembly and the item in the diagram For example 3 1 indicates Assembly 3 and item number 1 in the table How to use this parts catalog 7 Parts catalog Machine Description type AIO Simplex Duplex Modem Hard drive ADF ADF Dupl...

Page 580: ...7 2 Service Manual Assembly 1 Covers X651 X652 5535dn X654 and X656 ...

Page 581: ...bly MFP X651 X652 X654 and X656 19 40X4377 1 1 USB cable assembly X651 X652 X654 and X656 20 40X4503 1 1 Operator panel door assembly with hinges X654 and X656 20 40X2149 1 1 Operator panel door assembly with hinges X651 and X652 21 40X4000 1 1 X654de touch screen bezel 21 40X4121 1 1 X656de touch screen bezel 21 40X4123 1 1 X651de touch screen bezel 21 40X5757 1 1 X652de touch screen bezel 22 40X...

Page 582: ...7 4 Service Manual Assembly 2 Covers 1 X658 1 2 3 5 4 6 7 8 9 10 11 12 13 14 15 16 10 17 18 19 21 20 20 ...

Page 583: ...ar X658 8 40X4478 1 1 Side cover right X658 9 40X1976 1 1 Tray cover right X658 10 40X4483 2 1 MPF tray cover support strap X658 11 40X4485 1 1 Inner cover right X658 12 40X7047 1 1 MPF media guide assembly X658 13 40X2016 1 1 MPF tray cover assembly X658 14 40X1915 1 1 Model door bezel X658 15 40X4484 1 1 Inner cover left X658 16 40X1975 1 1 Tray cover left X658 17 40X4476 1 1 Side cover left X65...

Page 584: ...7 6 Service Manual Assembly 3 Covers 2 X658 ...

Page 585: ... 1 1 Scanner support cover left X658 11 40X4519 1 1 Scanner support inner cover left X658 12 40X4525 1 1 Standard output bin LED assembly 13 40X4499 1 1 Standard output bin LED cable assembly X656 14 40X4504 1 1 Operator panel assembly X658 15 40X4599 1 1 Operator panel cover with card reader slot X658 16 40X2018 1 1 Operator panel front cover X658 17 40X4602 1 1 Card reader assembly 3121 contact ...

Page 586: ...7 8 Service Manual Assembly 4 Media path and ducts ...

Page 587: ... brush 5 40X1900 1 1 Media turn guide with actuator 6 40X4388 1 1 Inner deflector 7 40X4406 2 1 Print cartridge support roller 8 40X4395 1 1 Tray roller catch assembly 9 40X4394 1 1 Tray catch spring 10 40X4385 1 1 Envelope feeder interface cover X658 only 11 40X1876 1 1 MPF gear shield 12 40X4389 1 1 LVPS cooling duct 13 40X4486 1 1 Main cooling fan duct X658DE 13 40X4392 1 1 Main cooling duct X6...

Page 588: ...7 10 Service Manual Assembly 5 Pick arm and media tray assemblies ...

Page 589: ...pick solenoid assembly 3 40X1883 1 1 MPF pick roll assembly with flange and clip 4 40X4457 1 1 MPF cam gear 5 40X4469 1 1 Media tray assembly 550 sheet X651 X652 X654 and X656 5 40X2164 1 1 Media tray assembly X658 6 40X4472 1 1 Switch media size assembly 7 40X4307 1 1 Pick arm spring 8 40X4308 1 2 Pick roll assembly 2 9 40X4310 1 1 550 Sheet media out actuator 10 40X4305 1 1 550 Sheet pick arm as...

Page 590: ...7 12 Service Manual Assembly 6 Drive motor assembly redrive and duplex 2 3 5 4 6 7 8 11 13 12 9 10 14 15 16 17 18 19 1 ...

Page 591: ...ght 8 40X4348 1 1 Duplex guide assembly front 9 40X5551 1 1 Duplex guide spring left 10 40X4369 1 1 Sensor duplex input 11 40X4345 1 1 Duplex input sensor assembly 12 40X4350 1 1 Duplex drive belt lower 13 40X4354 1 1 Duplex drive belt upper 14 40X4303 1 3 Alignment assembly with ground strap and adj screw 15 40X4473 1 2 Option drive shaft with spring 16 99A0954 1 1 Bevel gear with grease packet a...

Page 592: ...7 14 Service Manual Assembly 7 Printhead charge and transfer assembly 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 593: ...nk spring right 4 40X1888 1 2 Transfer roll bracket assembly right 5 40X1886 1 1 Transfer roll assembly with tool 6 40X1887 1 2 Transfer roll bracket with cable assembly left 7 40X5852 1 1 Charge roll assembly with tool 8 40X4316 1 1 Charge roll link spring left 9 40X1864 1 1 Print cartridge ID connector assembly 10 40X4364 1 1 Main cooling fan 11 40X4372 1 1 Sensor standard bin exit actuator asse...

Page 594: ...7 16 Service Manual Assembly 8 System card HVPS and scanner controller card assemblies X658 only ...

Page 595: ...ard power cable assembly 15 40X2074 1 1 Scanner controller card assembly X651 and X652 15 40X2075 1 1 Scanner controller card assembly X654 X656 and X658 16 40X4376 1 1 Output option interface cable assembly X658 17 40X4498 1 1 LVPS cooling fan cable assembly Warning When replacing any of the following components Scanner interface card assembly System card assembly Scanner unit assembly Only repla...

Page 596: ...7 18 Service Manual Assembly 9 Fuser and LVPS card assemblies ...

Page 597: ...assembly 110V type 2 1 40X5855 1 1 Fuser assembly 220V type 2 2 40X4419 1 1 Fuser interface cable assembly 3 40X2062 1 1 LVPS card assembly X651 X652 X654 and X656 3 40X2072 1 1 LVPS card assembly X658 4 40X4359 1 1 Print cartridge cooling fan 5 40X4356 1 1 Duplex cooling fan 6 40X4360 1 1 Print cartridge cooling fan cable assembly 7 40X4357 1 1 Duplex cooling fan cable assembly 8 40X1866 1 1 Sens...

Page 598: ...7 20 Service Manual Assembly 10 Flatbed scanner ...

Page 599: ...rriage belt tensioner assembly 16 40X4535 1 1 Scanner cooling fan 17 40X4536 1 1 Scanner cooling fan filter 18 40X7204 1 1 Scanner filter cover 19 40X4531 1 1 Scanner CCD ribbon cable X658 Warning When replacing any of the following components Scanner interface card assembly System card assembly Scanner unit assembly Only replace one component at a time replace the required component and perform a...

Page 600: ...7 22 Service Manual Assembly 11 ADF unit assembly 1 ...

Page 601: ...Parts catalog 7 23 Assembly 11 ADF unit assembly Asm index Part number Units option Units FRU Description 1 40X2738 1 1 ADF unit assembly X651 and X652 1 40X2745 1 1 ADF unit assembly X654 X656 and X658 ...

Page 602: ...7 24 Service Manual Assembly 12 ADF covers ...

Page 603: ... left X651 and X652 4 40X4563 1 1 Right hinge assembly 5 40X4539 1 1 ADF cover rear 6 40X4564 1 1 Document tray extension 7 40X3444 1 1 ADF platen cushion 8 40X3392 1 1 ADF lower door assembly X651 and X652 8 40X3438 1 1 ADF lower door assembly X654 X656 and X658 9 40X3445 1 1 Media pinch pad assembly 10 40X4538 1 1 ADF cover front 11 40X4566 1 1 ADF turn guide 12 40X4562 1 1 Pick pad cover assemb...

Page 604: ...7 26 Service Manual Assembly 13 ADF feed and drive 3 11 7 13 5 9 2 10 6 4 12 8 1 ...

Page 605: ...44 1 1 Transport motor bracket assembly with cable 5 40X2759 1 4 Transport drive gear and pulley kit rear 6 40X2749 1 4 Feed one way bearing and gear kit 7 40X4542 1 1 Pinch roll assembly 8 40X2760 1 9 Transport drive gear pulley and belt kit front 9 40X4548 1 1 ADF solenoid assembly 10 40X2761 1 4 Pick roll position cam assembly 11 40X4605 1 2 ADF separator roll and guide 12 40X7214 1 1 Torque li...

Page 606: ...7 28 Service Manual Assembly 14 ADF electronics ...

Page 607: ...DF interface cable assembly 9 40X4557 1 1 ADF closed interlock switch cable assembly 10 40X3142 1 1 ADF controller card assembly 11 40X4554 1 1 Switch ADF closed interlock 12 40X4555 1 1 Duplex CCD interface cable assembly X654 X656 and X658 13 40X3272 1 1 ADF duplex deletion insert X651 and X652 14 40X4565 1 1 ADF duplex CCD scan glass assembly X654 X656 and X658 15 40X4547 1 1 ADF duplex CCD ass...

Page 608: ...7 30 Service Manual Assembly 15 550 Sheet option tray assembly X658 ...

Page 609: ...ator 8 40X4570 2 2 Anti tip latch assembly 9 40X5843 1 1 550 Sheet option drawer assembly 10 40X3822 1 1 Media tray catch spring 11 40X4395 1 1 Media tray roller catch assembly 12 40X1976 1 1 550 Sheet tray right cover 13 40X2164 1 1 Media tray assembly 550 sheet 14 40X4130 1 1 Cover 550 sheet tray front 15 40X1975 1 1 550 Sheet tray left cover 16 40X4575 1 1 Sensor pass through with cable 17 40X4...

Page 610: ...7 32 Service Manual 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 X654 and X656 Assembly 16 250 Sheet option tray assembly X651 X652 5535dn ...

Page 611: ...X651 and X652 8 40X4570 1 1 Anti tip latch assembly 9 40X3453 1 1 250 Sheet option drawer assembly 10 40X3822 1 1 Media tray catch spring 11 40X4395 1 1 Media tray roller catch assembly 12 40X6391 1 1 Media tray assembly 250 sheet 13 40X4575 1 1 Sensor pass through with cable 14 40X1863 1 1 250 Option drive shaft with spring 15 40X4572 1 1 Lower interface cable assembly 16 40X3854 1 1 Media size a...

Page 612: ...7 34 Service Manual X654 and X656 Assembly 17 550 Sheet option tray assembly X651 X652 5535dn ...

Page 613: ...tuator 8 40X4570 2 2 Anti tip latch assembly 9 40X3957 1 1 550 Sheet option drawer assembly 10 40X3822 1 1 Media tray catch spring 11 40X4395 1 1 Media tray roller catch assembly 12 40X4469 1 1 Media tray assembly 550 sheet 13 40X4575 1 1 Sensor pass through with cable 14 40X4473 1 1 550 Option drive shaft with spring 15 40X4572 1 1 Lower interface cable assembly 16 40X3854 1 1 Media size actuator...

Page 614: ...7 36 Service Manual 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 14 17 15 18 19 20 21 22 X654 and X656 Assembly 18 HCIT Sheet option tray assembly X651 X652 5535dn ...

Page 615: ...4570 1 1 Anti tip latch assembly 11 40X4588 1 1 Sensor HCIT tray raised HP with cable assembly 12 40X4582 1 1 HCIT cover right 13 40X4586 1 1 HCIT tray lift drive motor assembly 14 40X4585 1 2 HCIT tray closed latch with spring 15 40X4593 2 1 HCIT drawer slide assembly 16 40X4580 1 2 HCIT media tray assembly 17 40X4584 1 1 HCIT tray cover front 18 40X4589 1 2 Sensor HCIT pass through with cable 19...

Page 616: ...7 38 Service Manual Assembly 19 MFP stapler assembly 1 ...

Page 617: ...Parts catalog 7 39 Assembly 19 MFP stapler assembly 1 Asm Index Part number Units mach Units kit or pkg Description 1 40X7026 1 1 MFP stapler assembly comes completely assembled ...

Page 618: ...7 40 Service Manual Assembly 20 MFP stapler assembly 2 2 1 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 ...

Page 619: ... receive 7 40X4617 1 2 Finisher bin spring 8 40X5545 1 1 Standard output bin LED 9 40X5727 1 1 LED clear lens 10 40X5720 1 1 LED sensor cover 11 40X4618 1 1 Sensor finisher bin media present 12 40X4619 1 1 Media output bin extension 13 40X5541 1 1 Media output bin 14 40X4626 1 1 Sensor bin full send 15 40X4625 1 1 Stapler stacker controller card assembly 16 40X5751 1 1 Attach roller 17 40X4609 1 1...

Page 620: ...7 42 Service Manual Assembly 21 MFP stapler assembly 3 4 5 1 2 3 6 6 7 8 9 10 11 ...

Page 621: ...or 2 40X4646 1 1 Media stack flap 3 40X4369 1 1 Sensor media stack 4 40X4621 1 1 Left tamper motor assembly 5 40X4622 1 1 Right tamper motor assembly 6 40X4624 1 2 Tamper recoil spring 7 40X4369 1 1 Sensor tamper HP right 8 40X4369 1 1 Sensor tamper HP left 9 40X4623 1 1 Tamper drive belt 10 40X4369 1 1 Sensor paddle HP 11 40X4615 1 1 Paddle drive motor ...

Page 622: ...7 44 Service Manual Assembly 22 MFP stapler assembly 4 1 2 ...

Page 623: ...Parts catalog 7 45 Assembly 22 MFP stapler assembly 4 Asm Index Part number Units mach Units kit or pkg Description 1 40X4641 1 1 Stapler assembly 2 40X5909 1 1 Sensor media in stapler ...

Page 624: ...7 46 Service Manual Assembly 23 MFP offset stacker assembly 1 1 ...

Page 625: ...Parts catalog 7 47 Assembly 23 MFP offset stacker assembly 1 Asm Index Part number Units mach Units kit or pkg Description 1 40X7025 1 1 MFP offset stacker assembly comes completely assembled ...

Page 626: ...7 48 Service Manual Assembly 24 MFP Offset stacker 2 4 3 2 1 5 6 7 8 9 10 11 12 13 14 16 17 15 18 ...

Page 627: ...4617 1 2 Finisher bin spring 7 40X5545 1 1 Standard output bin LED 8 40X5727 1 1 LED clear lens 9 40X5720 1 1 LED sensor cover 10 40X4618 1 1 Sensor finisher bin media present 11 40X4619 1 1 Media output bin extension 12 40X5541 1 1 Media output bin 13 40X4626 1 1 Sensor bin full send 14 40X4625 1 1 Stapler stacker controller card assembly 15 40X5751 1 1 Attach roller 16 40X4609 1 1 Left cover 17 ...

Page 628: ...7 50 Service Manual Assembly 25 MFP Offset stacker 3 4 5 1 2 3 6 6 7 8 9 10 11 ...

Page 629: ...r 2 40X4646 1 1 Media stack flap 3 40X4369 1 1 Sensor media stack 4 40X4621 1 1 Left tamper motor assembly 5 40X4622 1 1 Right tamper motor assembly 6 40X4624 1 2 Tamper recoil spring 7 40X4369 1 1 Sensor tamper HP right 8 40X4369 1 1 Sensor tamper HP left 9 40X4623 1 1 Tamper drive belt 10 40X4369 1 1 Sensor paddle HP 11 40X4615 1 1 Paddle drive motor ...

Page 630: ...7 52 Service Manual Assembly 26 MFP 4 bin mailbox assembly 1 1 ...

Page 631: ...Parts catalog 7 53 Assembly 26 MFP 4 bin mailbox assembly 1 Asm Index Part number Units mach Units kit or pkg Description 1 40X7024 1 1 MFP 4 bin mailbox assembly comes completely assembled ...

Page 632: ...7 54 Service Manual Assembly 27 MFP 4 bin mailbox assembly 2 3 2 4 5 11 8 9 10 7 1 6 ...

Page 633: ...edia bin bail 2 40X4642 1 1 Top cover 3 40X4135 3 1 1st 3rd media bail 4 40X4640 1 1 Left cover 5 40X4638 1 1 Left rear inner cover 6 40X4369 1 1 Sensor deflector gate HP 7 40X4632 1 1 Rear door assembly 8 40X4637 1 1 Right rear inner cover 9 40X4639 1 1 Right cover 10 40X4636 1 1 LED card assembly 11 40X4139 4 1 Media output bin light pipe ...

Page 634: ...7 56 Service Manual Assembly 28 MFP 4 bin mailbox assembly 3 1 2 3 4 5 6 7 8 9 9 9 9 10 11 12 4 8 8 8 ...

Page 635: ...rough 3 40X4635 3 1 Deflector gate solenoid 4 40X5751 1 1 Attach roller 5 40X5545 1 1 Standard output bin LED 6 40X5727 1 1 LED clear lens 7 40X4647 1 1 Output bin LED bracket 8 40X4136 4 1 Media bin full actuator 9 40X4633 4 1 Sensor media bin full 10 40X4643 1 1 Transport solenoid 11 40X4634 1 1 4 bin mailbox controller card assembly 12 40X4138 4 1 Media bin deflector ...

Page 636: ...7 58 Service Manual Assembly 29 Envelope feeder 1 ...

Page 637: ...Parts catalog 7 59 Assembly 29 Envelope feeder Asm Index Part number Units mach Units kit or pkg Description 1 40X5739 1 1 Envelope feeder X658 only ...

Page 638: ...d available w EMEA AP LAD NS 40X6200 1 1 Forms card with P269UBC code for UBOC NS 40X1556 1 1 Parts pack ISP thumbscrew and standoff NS 40X5316 1 1 ISP interface cable assembly NS 40X4826 1 1 MarkNet N8120 gigabit ethernet print server NS 40X4827 1 1 MarkNet N8130 fiber ethernet print server NS 40X5038 1 1 MarkNet N8150 802 11n wireless print server US Americas NS 40X5039 1 1 MarkNet N8150 802 11n...

Page 639: ...er Units mach Units kit or pkg Description NS 40X1462 1 1 Locking universal media drawer with tray 200 sheet excluding X658 NS 40X1463 1 1 Locking media drawer with tray 550 sheet excluding X658 NS 40X1464 1 1 Locking universal media drawer with tray 400 sheet excluding X658 ...

Page 640: ...S 40X4596 1 1 Power cord LV Brazil PPB kits NS 40X0271 1 1 Power cord HV Asian Brunei Cambodia Indonesia Laos Malaysia Myanmar Philippines Singapore Thailand Vietnam Afghanistan Bangladesh Bhutan India Nepal Pakistan Sri Lanka Tibet Hong Kong NS 40X0301 1 1 Power cord HV Australia New Zealand NS 40X3609 1 1 Power cord 100 V Japan NS 40X1792 1 1 Power cord HV Korea NS 40X0303 1 1 Power cord HV PRC ...

Page 641: ...sal media tray 400 sheet X651 X652 X654 and X656 NS 40X7001 1 1 Wear strips smooth 250 sheet NS 40X7002 1 1 Wear strips dimpled 250 sheet NS 99A1206 1 1 Wear strips 3 row dimpled 250 sheet NS 40X2786 1 1 Wear strips 4 row dimpled 250 sheet NS 40X7003 1 1 Wear strips 3 row dimpled 550 sheet NS 40X7004 1 1 Wear strips dinky 550 sheet NS 40X2787 1 1 Wear strips 3 row dimpled 550 sheet NS 40X2788 1 1 ...

Page 642: ...7 64 Service Manual ...

Page 643: ...ry defaults 3 33 US Non US defaults 3 22 diagnostic information confirm the installation status 2 2 Power on Reset sequence 2 2 diagnostics error code table 2 11 diagnostics menu accessing 3 7 available tests 3 8 BASE SENSOR TEST 3 20 DEVICE TESTS Disk Test Clean 3 21 Quick Disk Test 3 21 DUPLEX TESTS Duplex Feed 1 3 18 Duplex Feed 2 3 18 Motor Test 3 17 Quick Test 3 16 Sensor Test 3 17 Top Margin...

Page 644: ... black 2 157 troubleshooting 2 152 2 172 vertical blank lines white stripes in media transport direction 2 158 image quality troubles after image 2 166 background fog 2 167 horizontal band printheads out 2 159 horizontal stripes 2 161 media damage 2 169 2 178 no fuse 2 171 partial lack 2 163 skew 2 168 2 177 spots 2 164 2 175 vertical stripes 2 160 2 174 input sensor tray tests 3 19 input source t...

Page 645: ... sensor MPF media width 3 49 names and functions of components 3 68 3 71 ADF 3 71 scanner unit assembly 3 68 printhead assembly 3 53 front thermistor 3 56 fuser exit sensor 3 56 heat roll 3 55 pressure belt 3 56 thermostat 3 56 registration 3 51 sensor registration 3 51 standard media exit roll assembly sensor standard bin full 3 58 transfer 3 52 2nd transfer roll assembly 3 52 xerographic process...

Page 646: ...I 4 Service Manual ...

Page 647: ...70 Laser cover assembly 550 sheet X658 7 5 40X1974 Stapler access cover X658 7 7 40X1975 550 Sheet tray left cover 7 31 40X1975 Tray cover left X658 7 5 40X1976 550 Sheet tray right cover 7 31 40X1976 Tray cover right X658 7 5 40X1977 Print cartridge cover assembly X658 7 5 40X2016 MPF tray cover assembly X658 7 5 40X1916 Side cover left X651 X652 5535dn X654 and X656 40X1556 Parts pack ISP thumbs...

Page 648: ...ly 7 33 40X3448 250 Sheet bellcrank recoil spring 7 33 40X3453 250 Sheet option drawer assembly 7 33 40X3454 550 Sheet pick arm bracket assembly 7 31 7 35 40X3609 Power cord 100 V Japan 7 62 40X3822 Media tray catch spring 7 31 7 33 7 35 40X3854 Media size actuator 7 31 7 33 7 35 40X3957 550 Sheet option drawer assembly 7 35 40X3967 Complete 550 sheet option tray assembly X658 7 31 40X4000 X654de ...

Page 649: ...19 40X4357 Duplex cooling fan cable assembly 7 19 40X4359 Print cartridge cooling fan 7 19 40X4360 Print cartridge cooling fan cable assembly 7 19 40X4361 HVPS sensor cable assembly 7 17 40X4362 HVPS card assembly 7 17 40X4364 Main cooling fan 7 15 40X4365 MPF pick solenoid assembly 7 11 40X4368 Sensor input 7 17 40X4369 Sensor deflector gate HP 7 55 40X4369 Sensor duplex input 7 13 40X4369 Sensor...

Page 650: ...4493 Scanner controller card interface cable assembly 7 17 40X4496 Scanner controller card power cable assembly 7 17 40X4498 LVPS cooling fan cable assembly 7 17 40X4499 Standard output bin LED cable assembly X656 7 7 40X4500 USB cable assembly X658 7 7 40X4501 System card assembly 7 17 40X4503 Operator panel door assembly with hinges X654 and X656 7 3 40X4504 Operator panel assembly X658 7 7 40X4...

Page 651: ...nsor ADF sheet through 7 29 40X4551 Sensor ADF document set 7 29 40X4554 Switch ADF closed interlock 7 29 40X4555 Duplex CCD interface cable assembly X654 X656 and X658 7 29 40X4556 ADF interface cable assembly 7 29 40X4557 ADF closed interlock switch cable assembly 7 29 40X4558 ADF sensor cable assembly 1 7 29 40X4559 ADF tray length cable assembly 7 29 40X4560 ADF sensor cable assembly 2 7 29 40...

Page 652: ...4618 Sensor finisher bin media present 7 41 7 49 40X4619 Media output bin extension 7 41 7 49 40X4621 Left tamper motor assembly 7 43 7 51 40X4622 Right tamper motor assembly 7 43 7 51 40X4623 Tamper drive belt 7 43 7 51 40X4624 Tamper recoil spring 7 43 7 51 40X4625 Stapler stacker controller card assembly 7 41 7 49 40X4626 Sensor bin full send 7 41 7 49 40X4629 Connection bezel assembly rear 7 3...

Page 653: ... LED sensor cover 7 41 7 49 40X5727 LED clear lens 7 41 7 49 7 57 40X5728 Sensor pass through 7 57 40X5739 Envelope feeder X658 only 7 59 40X5749 Main drive motor assembly with option drive shaft 7 13 40X5750 Spring 7 57 40X5751 Attach roller 7 41 7 49 7 57 40X5757 X652de touch screen bezel 7 3 40X5843 550 Sheet option drawer assembly 7 31 40X5850 Redrive motor assembly 7 13 40X5851 Duplex drive m...

Page 654: ...s completely assembled 7 47 40X7026 MFP stapler assembly comes completely assembled 7 39 40X7035 Hard drive cooling fan 7 17 40X7204 Scanner filer cover 7 21 40X7213 Feed motor assembly with belt and cable 7 27 40X7214 Torque limiter 7 27 7377730 Relocation kit X658 7 60 99A0954 Bevel gear with grease packet and washer 7 13 99A1206 Wear strips 3 row dimpled 250 sheet 7 63 40X7047 MPF media guide a...

Page 655: ...b 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 88 0 mm 3 46 in 51 7 mm 2 04 in Replace the charge rollers 28 3 mm 1 11 in...

Page 656: ...3 2 1 3 4 6 8 10 5 7 9 11 14 Fax Card Assembly To J31 2 To J32 1 To J22 2 To J22 1 To J32 3 To J32 4 To J32 2 To J22 4 To J22 3 Power Switch F2 250V CR08 250V Fuser Power TBD 1 2 1 2 CN3 1 3 2 JDC1 JDC2 AIO POWER S HOP LED GND S HOP FULL RDRV MOT 24V RDRV MOT 24V GND S RDRV FEEDBACK S RDRV FEEDBACK LED L ENB CN GND L ADJ 0 CN GND L POW CN S 5 PHEAD GND VID 0 CN VID 0 CN L ADJ 1 CN GND VID 1 CN VID...

Page 657: ...ROUGH CN11 CN2 1 2 3 SENSOR FB LENGTH 3 1 2 3 SENSOR FB LENGTH 1 24V FEED 24V FEED NTOP FB GND MDC RXD SCAN OUT nA SCAN OUT nB nADF INTERVAL SEN nFLAT LENGTH 2 SEN nHOME SEN 5V GND 24V TP FB 24V TP FB GND nTOP ADFGND 5VFB LED ON MDC TXD nCOVER CLOSING SEN GND SCAN OUT ASCAN OUT nA SCAN OUT A SCAN OUT BSCAN OUT nB SCAN OUT B GND nFLAT LENGTH1 SEN nFLAT LENGTH 3 SEN GNDFB FAN ON FB FAN BACK nRESET 2...

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