Dell Multifunction Laser Printer 5535dn Service manual

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Table of contents
Table of contents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
Notices and safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xv
Laser notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
Lithium warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xxi
Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxi
Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xxiv
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Maintenance approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Printer overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Printer configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Basic models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Available internal options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Media handling options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Supported paper sizes, types, and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Paper sizes supported by the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Paper types and weights supported by the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Paper types and weights supported by the output bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Tools required for service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Diagnostic information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Confirm the installation status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Power-on Reset sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Entering Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
User attendance messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Error code table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11
Service checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-107
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 (duplex exit) service check (external duplex only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109
Sensor (pass through) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-109
Sensor (envelope feeder empty) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-110
Sensor (ADF top door interlock) service check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-110
Switch (ADF closed interlock) jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-111
Sensor (ADF sheet through) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112
Sensor (ADF sheet through) late jam service check 290.01 . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-113
Sensor (ADF 1st scan) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-114
Sensor (ADF sheet through) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115
Sensor (1st scan) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-117
Sensor (2nd scan) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118
Sensor (2nd scan) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-118
Sensor (ADF media exit) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-119
ADF top door open jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-121
Media missing jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-121
Table of contents
iii
Sensor (ADF media exit) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (ADF media exit) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (ADF media exit) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (input) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (input) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (input) early jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (input) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (fuser output) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (fuser output) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (fuser output) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (narrow media) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (narrow media) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (duplex input) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (duplex input) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (duplex input) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (pass through) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (pass through) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (pass through) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (stapler pass through) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (stapler pass through) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (stapler pass through) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (output pass through) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (output pass through) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (output pass through) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (mailbox empty) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (mailbox empty) lingering jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (mailbox empty) static jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (toner empty) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (scanner HP) service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (ADF 2nd scan) late jam service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NVRAM mismatch failure (950.00 through 950.29) service check . . . . . . . . . . . . . . . . . . . . . .
Image quality trouble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Printer Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Image quality symptoms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faint print (Low contrast) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blank print (no print) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Solid black . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical lines and bands (process direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal white stripes or bands (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical stripes (process direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horizontal stripes (side to side direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Partial lack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
After image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Background (fog) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADF & Scanner Related Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Image quality symptoms: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADF & Scanner Image Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dark image quality (using ADF or Scanner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Vertical lines (process direction using the ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spots (using flatbed scanner) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Skew (using ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media damage (using ADF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network service check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Service Manual
2-122
2-123
2-125
2-127
2-129
2-130
2-131
2-132
2-133
2-135
2-135
2-136
2-137
2-139
2-140
2-141
2-142
2-143
2-144
2-144
2-145
2-145
2-146
2-146
2-147
2-147
2-148
2-149
2-149
2-149
2-150
2-151
2-151
2-151
2-152
2-152
2-154
2-156
2-157
2-158
2-159
2-160
2-162
2-163
2-165
2-166
2-167
2-168
2-170
2-171
2-171
2-172
2-172
2-173
2-174
2-176
2-177
2-178
Diagnostic aids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Understanding the printer control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Understanding the home screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Using the touch-screen buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Sample touch screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Other touch-screen buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Accessing service menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Entering Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Available tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Registration (printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Quick Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
PRINT TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Input source tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Printing Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
HARDWARE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Panel Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Button Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
DRAM Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
CACHE Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
USB HS Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
DUPLEX TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Quick Test (duplex) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
Top Margin (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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Permanent Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Engine Settings 1 through 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Model Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
Configuration ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Edge to Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Enable Edge to Edge Copy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
EP SETUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
EP Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Fuser Temperature (Fuser Temp) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Fuser Page Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Warm Up Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Print Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Charge Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Gap Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Auto Dark Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
REPORTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Table of contents
v
Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Display Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Print Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Clear Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
SCANNER TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Back Side Scan Uniformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
ASIC Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Feed Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Sensor Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Configuration menu (CONFIG MENU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Entering Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Available menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Maintenance Counter Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Reset Maintenance Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
USB Scan to Local . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Print Quality Pages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
SIZE SENSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
Panel Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
PPDS Emulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Energy Conserve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33
Min Copy Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
NumPad Job Assist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Format 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 Custom Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40
Exit Configuration Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-41
Printer configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Basic models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
Printer theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors . . . . . . . . . . . . . . . . 3- 43
Model X658 paper path rolls and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-46
Detection of media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
vi Service Manual
Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Sensor (media empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-47
Sensor (media low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Multi-purpose feeder (MPF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
MPF feed roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
MPF pick solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-48
Sensor (MPF media empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Supported paper sizes, types, and weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Paper sizes supported by the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-49
Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Sensor (input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Alignment assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-51
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
Transfer roll assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-52
Polygon printhead assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-53
Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-54
Fuser components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
Heat roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-55
Pressure roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Heater lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Thermal cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Thermistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Sensor (fuser output) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Sensor (narrow media) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-56
Fuser unit assembly (type 1 and type 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-60
System card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Printhead control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Rotation of printhead motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Determination of printhead ready . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Printhead reference value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Fuser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Fuser control method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Fuser lamp on/off control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-61
Fuser warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
Xerographic and print cartridge components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-62
Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-63
Development . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-64
Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-65
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-66
Auto density sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-67
Document scanning at ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-68
Table of contents
vii
Document scanning at platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Names and functions of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Scanner unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Sensor (FB length APS 1), Sensor (FB length APS 2), Sensor (FB length APS 3) . . . . . . . . . 3-68
Switch (ADF closed interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Scanner drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68
Sensor (FB scanner HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Scanner exposure lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Scanner controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Scanner cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Setting a document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Preparation for feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-69
Simplex and duplex document feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Duplex document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70
Names and functions of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Sensor (ADF long media) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Sensor (ADF width 1), Sensor (ADF width 2), Sensor (ADF width 3), Sensor (ADF width 3) . . 3-71
Sensor (ADF document set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
ADF Document Set LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Switch (ADF top door interlock) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
ADF controller card assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-71
Sensor (ADF sheet through) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72
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
Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors. . . . . . . . . . . . . . . . . 3-78
Model X658 paper path rolls and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Rear media guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Side guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-79
Wear strips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Media tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Detection of media size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-80
Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Sensor (media empty) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Sensor (media low) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-81
Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Functions of main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Sensor (duplex input) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Duplex drive motor assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-82
Paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
Understanding jam numbers and locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
200 and 203 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-83
202 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85
230–239 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-85
viii Service Manual
240–245 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-87
250 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88
260 paper jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-88
270–279 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
28X staple jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-89
290–294 paper jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-91
Adjusting skew . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-93
Flatbed scanner skew adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
ADF skew adjustment (via ADF document tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-94
ADF skew adjustment (Via duplex CCD assembly) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-96
Media squareness check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-98
Print skew correction procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-101
Copy skew correction procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-103
Security Reset Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105
Security Reset Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-105
Printer skew specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
Abnormal skew printer correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-107
Print Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
Print Position Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-108
Repair information
.....................................................................
4-1
Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Polygon printhead mechanical registration adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Alignment assembly adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Fuser solenoid adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Gap adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Removal procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Before starting service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Charge 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 cover assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
HVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Inner deflector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Option drive shaft removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Main drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-20
Alignment assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-21
Media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Media support removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-23
Tray roller catch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
MPF cam gear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
MPF lift plate assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
MPF media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25
MPF pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
MPF pick solenoid assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26
Pick arm assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
Pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Print cartridge cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
Print cartridge clamp assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
Print cartridge ID connector assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
Table of contents
ix
Printhead assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
Connection access cover, rear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Door assembly, rear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Duplex guide assembly, rear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
Cover assembly, rear lower (X654, X656, and X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Redrive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
Sensor (duplex input) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Sensor (media low) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Sensor (media empty) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Sensor (toner empty) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
Sensor (input) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Sensor shield assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
Standard bin actuator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Sensor (standard bin exit) actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
Sensor (toner density) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
Switch (media size) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
LVPS card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Access door removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
System card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Hard drive removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
Hard drive cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
Fax card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
Transfer roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
Transfer roll bracket assembly, left removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Transfer roll bracket assembly, right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
Transfer deflector removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
Redrive assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
ADF feed / pick roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
ADF separator roll removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
ADF 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
ADF pinch roll assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
ADF turn guide removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
ADF media pinch pad assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
Sensor (ADF media exit) fan bracket assembly removal (X654, X656, and X658) . . . . . . . . . . . 4-76
ADF transport drive motor bracket assembly w/cable removal . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
ADF feed drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
ADF pick roll position cam assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
ADF solenoid assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Sensor (ADF top door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
Sensor (ADF lower door interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Sensor (ADF 2nd scan) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81
Sensor (ADF 1st scan) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Sensor (ADF sheet through) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
Sensor (ADF document set) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
Switch (ADF closed interlock) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84
ADF unit assembly removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . . 4-85
ADF unit assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
ADF left hinge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
ADF right hinge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
Cover, left rear corner removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88
x Service Manual
Cover, right rear corner removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-88
Sensor (standard bin exit) actuator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-89
Sensor (ADF media exit) bracket assembly removal (X651) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-90
Scanner CCD assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-91
Scanner reference LED cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-93
Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . .4-94
Scanner unit assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96
MPF tray door assembly removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . .4-97
MPF tray door assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-99
Fuser access assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-101
Output cover assembly removal (model X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . .4-101
Output cover assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-102
Redrive assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-103
Redrive assembly removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . .4-103
Laser cover removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104
Laser cover removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . . . . . . .4-106
Standard output bin LED assembly removal (models X651, X652/5535dn, X654, and X656) . .4-108
MPF media guide assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-108
Operator panel assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-109
Card reader assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-111
USB cable removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-114
Operator panel door assembly removal (models X651, X652/5535dn, X654, and X656) . . . . . .4-115
Operator panel cover latch assembly removal (models X651, X652/5535dn, X654,
and X656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-119
Print cartridge cover assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-120
Side cover, right removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-121
Side cover, right removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . . . .4-122
Side cover, left removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-123
Side cover, left removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . . . . .4-123
Door assembly, rear 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 cover, left removal (models X651, X652/5535dn, X654 and X656) . . . . . . . . . . . . . . . .4-134
Scanner cover, left removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-135
Scanner cover, right removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . .4-136
Scanner cover, right removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-136
Scanner cover, front removal (models X651, X652/5535dn, X654 and X656) . . . . . . . . . . . . . . .4-137
Scanner cover, front removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-137
Scanner platen glass cover assembly removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . .4-139
Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654,
and X656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-140
Scanner support platform removal (models X651, X652/5535dn, X654, and X656) . . . . . . . . . .4-141
Carriage belt tensioner assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-143
Carriage drive motor assembly with cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144
Carriage belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-145
Scanner / ADF duplex CCD exposure lamp removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-147
Scanner interface card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-148
Scanner cooling fan filter removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149
Scanner cooling fan removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-149
Scanner support cover, left rear removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-150
Scanner support cover, left front removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-151
Scanner support cover, left removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-152
Scanner support inner cover, left removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-152
Sensor (platen glass length) assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-153
Table of contents
xi
Sensor (scanner HP) assembly w/bracket removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LVPS cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Option removals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) media tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) tray cover, front removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) cover, rear removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) cover, right removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) cover, left removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) anti-tip latch assembly removal . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) drawer slide assembly removal . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) tray lift drive motor assembly removal . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) controller card assembly removal . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) media size actuator assembly removal . . . . . . . . . . . . . . . . .
Sensor (HCIT tray raised HP) with cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (HCIT pass through) with cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) pick arm bracket assembly removal . . . . . . . . . . . . . . . . . . .
High capacity input tray (HCIT) tray closed latch with spring removal . . . . . . . . . . . . . . . . . .
250-sheet media tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
250-sheet option drawer assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
250-sheet pick arm bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
250-sheet media out actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-tip latch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
250-sheet frame assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (pass through) with cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
250-sheet controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media size actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media tray catch spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tray roller catch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet option tray assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet media tray assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet option drawer assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet pick arm bracket assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet bellcrank recoil spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media out actuator removal (models T652 and T654) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Anti-tip latch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet frame assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper interface cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lower interface cable assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor (pass through) with cable removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media size actuator removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
550-sheet option drive shaft with spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media tray catch spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Media tray roller catch assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly rear door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly handle cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly LED sensor cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly sensor (finisher media bin present) removal . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly standard output bin LED and LED clear lens removal . . . . . . . . . . . .
MFP stapler assembly tamper drive belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly tamper drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly media stack flap and media stack flap actuator removal . . . . . . . . . .
MFP stapler assembly stapler unit assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stapler/stacker controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MFP stapler assembly paddle drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . .
xii Service Manual
4-154
4-154
4-156
4-156
4-157
4-158
4-160
4-162
4-164
4-165
4-167
4-167
4-169
4-170
4-172
4-173
4-175
4-177
4-178
4-178
4-179
4-180
4-180
4-181
4-181
4-184
4-186
4-187
4-188
4-190
4-191
4-191
4-192
4-193
4-193
4-194
4-195
4-197
4-197
4-198
4-198
4-200
4-201
4-202
4-202
4-203
4-203
4-204
4-204
4-205
4-206
4-208
4-208
4-209
4-210
4-210
4-212
4-213
4-213
MFP stapler assembly sensor (media stack) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-215
MFP stapler assembly sensor (paddle HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-215
MFP stapler assembly sensor (stapler access door interlock) removal . . . . . . . . . . . . . . . . . .4-216
MFP stapler assembly sensor (tamper HP left and right) removal . . . . . . . . . . . . . . . . . . . . . .4-217
MFP stapler assembly sensor (bin full send) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-217
MFP stapler assembly sensor (bin full receive) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-218
MFP stapler assembly sensor (media in stapler) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-219
MFP stapler assembly sensor (deflector HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-220
4-bin mailbox assembly left cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-221
4-bin mailbox assembly controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-221
4-bin mailbox assembly sensor (media bin full) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-222
4-bin mailbox assembly sensor (deflector gate HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-223
4-bin mailbox assembly rear door assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-224
4-bin mailbox assembly right cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-225
4-bin mailbox assembly LED card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-225
4-bin mailbox assembly top cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-226
4-bin mailbox assembly deflector gate solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-227
4-bin mailbox assembly transport solenoid removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-228
4-bin mailbox assembly spring removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-229
4-bin mailbox assembly deflector gate (bin 1 through 3) removal . . . . . . . . . . . . . . . . . . . . . . .4-230
4-bin mailbox assembly deflector gate (bin 4) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-231
4-bin mailbox assembly sensor (pass through) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-232
4-bin mailbox assembly sensor (mailbox 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 removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-239
Offset stacker LED sensor cover removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-240
Offset stacker sensor (finisher media bin present) removal . . . . . . . . . . . . . . . . . . . . . . . . . . .4-242
Offset stacker standard output bin LED and LED clear lens removal . . . . . . . . . . . . . . . . . . . .4-242
Offset stacker tamper drive belt removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-243
Offset stacker tamper drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-244
Offset stacker media stack flap and media stack flap actuator removal . . . . . . . . . . . . . . . . . .4-244
Stapler/stacker controller card assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-246
Offset stacker paddle drive motor assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-246
Offset stacker sensor (media stack) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-247
Offset stacker sensor (paddle HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-248
Offset stacker sensor (tamper HP left and right) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-249
Offset stacker sensor (bin full send) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-249
Offset stacker sensor (bin full receive) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-250
Offset stacker sensor (deflector HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-251
Connector locations
...................................................................
5-1
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Sensors–ADF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Sensors–Flatbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Safety inspection guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Lubrication specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Individual maintenance part expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Scheduled maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Maintenance kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Maintaining the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Cleaning the exterior of the printer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Table of contents
xiii
Cleaning the scanner glass . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Assembly 1: Covers (X651, X652/5535dn, X654, and X656) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Assembly 2: Covers 1 (X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Assembly 3: Covers 2 (X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Assembly 4: Media path and ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Assembly 5: Pick arm and media tray assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Assembly 6: Drive motor assembly, redrive, and duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Assembly 7: Printhead, charge, and transfer assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Assembly 8: System card, HVPS and scanner controller card assemblies . . . . . . . . . . . . . . . . . . . 7-16
Assembly 9: Fuser and LVPS card assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
Assembly 10: Flatbed scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Assembly 11: ADF unit assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Assembly 12: ADF covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Assembly 13: ADF feed and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Assembly 14: ADF electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Assembly 15: 550 Sheet option tray assembly (X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Assembly 16: 250 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) . . . . . . . . . . 7-32
Assembly 17: 550 Sheet option tray assembly (X651, X652/5535dn, X654, and X656) . . . . . . . . . . 7-34
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 stacker #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48
Assembly 25: MFP Offset stacker #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-50
Assembly 26: MFP 4-bin mailbox assembly #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52
Assembly 27: MFP 4-bin mailbox assembly #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
Assembly 28: MFP 4-bin mailbox assembly #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
Assembly 29: Envelope feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58
Assembly 30: Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-60
Assembly 31: Power cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
Assembly 32: Universal trays and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-63
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1
Part number index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
xiv Service Manual
Notices and safety information
The following laser notice labels may be affixed to this printer.
Laser notice
The printer is certified in the U.S. to conform to the requirements of DHHS 21 CFR Subchapter J for Class I (1)
laser products, and elsewhere is certified as a Class I laser product conforming to the requirements of IEC
60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength region of 770-795 nanometers.
The laser system and printer are designed so there is never any human access to laser radiation above a Class
I level during normal operation, user maintenance, or prescribed service condition.
Laser
Der Drucker erfüllt gemäß amtlicher Bestätigung der USA die Anforderungen der Bestimmung DHHS
(Department of Health and Human Services) 21 CFR Teil J für Laserprodukte der Klasse I (1). In anderen
Ländern gilt der Drucker als Laserprodukt der Klasse I, der die Anforderungen der IEC (International
Electrotechnical Commission) 60825-1 gemäß amtlicher Bestätigung erfüllt.
Laserprodukte der Klasse I gelten als unschädlich. Im Inneren des Druckers befindet sich ein Laser der Klasse
IIIb (3b), bei dem es sich um einen Galliumarsenlaser mit 5 Milliwatt handelt, der Wellen der Länge 770-795
Nanometer ausstrahlt. Das Lasersystem und der Drucker sind so konzipiert, daß im Normalbetrieb, bei der
Wartung durch den Benutzer oder bei ordnungsgemäßer Wartung durch den 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 Classe I sont considérés comme des produits non dangereux. Cette imprimante est
équipée d’un laser de Classe IIIb (3b) (arséniure de gallium d’une puissance nominale de 5 milliwatts) émettant
sur des longueurs d’onde comprises entre 770 et 795 nanomètres. L’imprimante et son système laser sont
conçus pour impossible, dans des conditions normales d’utilisation, d’entretien par l’utilisateur ou de révision,
l’exposition à des rayonnements laser supérieurs à des rayonnements de Classe I .
Avvertenze sui prodotti laser
Questa stampante è certificata negli Stati Uniti per essere conforme ai requisiti del DHHS 21 CFR Sottocapitolo
J per i prodotti laser di classe 1 ed è certificata negli altri Paesi come prodotto laser di classe 1 conforme ai
requisiti della norma CEI 60825-1.
I prodotti laser di classe non sono considerati pericolosi. La stampante contiene al suo interno un laser di classe
IIIb (3b) all’arseniuro di gallio della potenza di 5mW che opera sulla lunghezza d’onda compresa tra 770 e 795
nanometri. Il sistema laser e la stampante sono stati progettati in modo tale che le persone a contatto con la
stampante, durante il normale funzionamento, le operazioni di servizio o quelle di assistenza tecnica, non
ricevano radiazioni laser superiori al livello della classe 1.
Notices and safety information
xv
Avisos sobre el láser
Se certifica que, en los EE.UU., esta impresora cumple los requisitos para los productos láser de Clase I (1)
establecidos en el subcapítulo J de la norma CFR 21 del DHHS (Departamento de Sanidad y Servicios) y, en
los demás países, reúne todas las condiciones expuestas en la norma IEC 60825-1 para productos láser de
Clase I (1).
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene en su interior un láser de
Clase IIIb (3b) de arseniuro de galio de funcionamiento nominal a 5 milivatios en una longitud de onda de 770 a
795 nanómetros. El sistema láser y la impresora están diseñados de forma que ninguna persona pueda verse
afectada por ningún tipo de radiación láser superior al nivel de la Clase I durante su uso normal, el
mantenimiento realizado por el usuario o cualquier otra situación de servicio técnico.
Declaração sobre Laser
A impressora está certificada nos E.U.A. em conformidade com os requisitos da regulamentação DHHS 21 CFR
Subcapítulo J para a Classe I (1) de produtos laser. Em outros locais, está certificada como um produto laser da
Classe I, em conformidade com os requisitos da norma IEC 60825-1.
Os produtos laser da Classe I não são considerados perigosos. Internamente, a impressora contém um produto
laser da Classe IIIb (3b), designado laser de arseneto de potássio, de 5 milliwatts ,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 aan een laserprodukt van klasse I. Voor de Verenigde
Staten zijn deze eisen vastgelegd in DHHS 21 CFR Subchapter J, voor andere landen in IEC 60825-1.
Laserprodukten van klasse I worden niet als ongevaarlijk aangemerkt. De printer is voorzien van een laser van
klasse IIIb (3b), dat wil zeggen een gallium arsenide-laser van 5 milliwatt met een golflengte van 770-795
nanometer. Het lasergedeelte en de printer zijn zo ontworpen dat bij normaal gebruik, bij onderhoud of reparatie
conform de voorschriften, nooit blootstelling mogelijk is aan laserstraling boven een niveau zoals
voorgeschreven is voor klasse 1.
Lasermeddelelse
Printeren er godkendt som et Klasse I-laserprodukt, i overenstemmelse med kravene i IEC 60825-1.
Klasse I-laserprodukter betragtes ikke som farlige. Printeren indeholder internt en Klasse IIIB (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid laser, som arbejder på bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udformet således, at mennesker aldrig udsættes for en laserstråling over Klasse
I-niveau ved normal drift, brugervedligeholdelse eller obligatoriske servicebetingelser.
xvi Service Manual
Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR Subchapter J -standardin mukaiseksi luokan I (1) lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 770 - 795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.
Huomautus laserlaitteesta
Tämä kirjoitin on Yhdysvalloissa luokan I (1) laserlaitteiden DHHS 21 CFR Subchapter J -määrityksen mukainen
ja muualla luokan I laserlaitteiden IEC 60825-1 -määrityksen mukainen.
Luokan I laserlaitteiden ei katsota olevan vaarallisia käyttäjälle. Kirjoittimessa on sisäinen luokan IIIb (3b) 5
milliwatin galliumarsenidilaser, joka toimii aaltoalueella 770 - 795 nanometriä. Laserjärjestelmä ja kirjoitin on
suunniteltu siten, että käyttäjä ei altistu luokan I määrityksiä voimakkaammalle säteilylle kirjoittimen normaalin
toiminnan, käyttäjän tekemien huoltotoimien tai muiden huoltotoimien yhteydessä.
VARO! Avattaessa ja suojalukitus ohitettaessa olet alttiina näkymättömälle lasersäteilylle. 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 hälsovådliga. Skrivaren har en inbyggd laser av Klass IIIb (3b) som består av
en laserenhet av gallium-arsenid på 5 milliwatt som arbetar i våglängdsområdet 770-795 nanometer.
Lasersystemet och skrivaren är utformade så att det aldrig finns risk för att någon person utsätts för
laserstrålning över Klass I-nivå vid normal användning, underhåll som utförs av användaren eller annan
föreskriven serviceåtgärd.
Laser-melding
Skriveren er godkjent i USA etter kravene i DHHS 21 CFR, underkapittel J, for klasse I (1) laserprodukter, og er
i andre land godkjent som et Klasse I-laserprodukt i samsvar med kravene i IEC 60825-1.
Klasse I-laserprodukter er ikke å betrakte som farlige. Skriveren inneholder internt en klasse IIIb (3b)-laser, som
består av en gallium-arsenlaserenhet som avgir stråling i bølgelengdeområdet 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at personer aldri utsettes for laserstråling ut over klasse I-nivå under
vanlig bruk, vedlikehold som utføres av brukeren, eller foreskrevne serviceoperasjoner.
Notices and safety information
xvii
Avís sobre el Làser
Segons ha estat certificat als Estats Units, aquesta impressora compleix els requisits de DHHS 21 CFR, apartat
J, pels productes làser de classe I (1), i segons ha estat certificat en altres llocs, és un producte làser de classe
I que compleix els requisits d’IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. Aquesta impressora conté un làser de classe IIIb
(3b) d’arseniür de gal.li, nominalment de 5 mil.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 manteniment
d’usuari ni durant els serveis que satisfacin les condicions prescrites.
xviii Service Manual
Notices and safety information
xix
xx Service Manual
Lithium warning
CAUTION
This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturer’s instructions and local regulations.
Safety information
• The safety of this product is based on testing and approvals of the original design and specific
•
•
•
components. The manufacturer is not responsible for safety in the event of use of unauthorized
replacement parts.
The maintenance information for this product has been prepared for use by a professional service person
and is not intended to be used by others.
There may be an increased risk of electric shock and personal injury during disassembly and servicing of
this product. Professional service personnel should understand this and take necessary precautions.
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.
Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des
•
•
•
agréations portant sur sa conception d'origine et sur des composants particuliers. Le fabricant n'assume
aucune responsabilité concernant la sécurité en cas d'utilisation de pièces de rechange non agréées.
Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de
maintenance qualifié.
Le démontage et l'entretien 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 tension.
Norme di sicurezza
• La sicurezza del prodotto si basa sui test e sull'approvazione del progetto originale e dei componenti
•
•
•
specifici. Il produttore non è responsabile per la sicurezza in caso di sostituzione non autorizzata delle
parti.
Le informazioni riguardanti la manutenzione di questo prodotto sono indirizzate soltanto al personale di
assistenza autorizzato.
Durante lo smontaggio e la manutenzione di questo prodotto,
il rischio di subire scosse elettriche e danni alla persona è più elevato. Il personale di assistenza
autorizzato deve, quindi, adottare le precauzioni necessarie.
ATTENZIONE: Questo simbolo indica la presenza di tensione pericolosa nell'area del prodotto.
Scollegare il prodotto prima di iniziare o usare cautela se il prodotto deve essere alimentato per
eseguire l'intervento.
Notices and safety information
xxi
Sicherheitshinweise
• Die Sicherheit dieses Produkts basiert auf Tests und Zulassungen des ursprünglichen Modells und
•
•
•
bestimmter Bauteile. Bei Verwendung nicht genehmigter Ersatzteile wird vom Hersteller keine
Verantwortung oder Haftung für die Sicherheit übernommen.
Die Wartungsinformationen für dieses Produkt sind ausschließlich für die Verwendung durch einen
Wartungsfachmann bestimmt.
Während des Auseinandernehmens und der Wartung des Geräts besteht ein zusätzliches Risiko eines
elektrischen Schlags und körperlicher Verletzung. Das zuständige Fachpersonal sollte entsprechende
Vorsichtsmaßnahmen treffen.
ACHTUNG: Dieses Symbol weist auf eine gefährliche elektrische Spannung hin, die in diesem
Bereich des Produkts auftreten kann. Ziehen Sie vor den Arbeiten am Gerät den Netzstecker des
Geräts, bzw. arbeiten Sie mit großer Vorsicht, wenn das Produkt für die Ausführung der Arbeiten
an den Strom angeschlossen sein muß.
Pautas de Seguridad
• La seguridad de este producto se basa en pruebas y aprobaciones del diseño original y componentes
•
•
•
específicos. El fabricante no es responsable de la seguridad en caso de uso de piezas de repuesto no
autorizadas.
La información sobre el mantenimiento de este 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 peligroso. Antes de empezar, desenchufe el equipo o tenga cuidado si, para
trabajar con él, debe conectarlo.
Informações de Segurança
• A segurança deste produto baseia-se em testes e aprovações do modelo original e de componentes
•
•
•
específicos. O fabricante não é responsável pela segunrança, no caso de uso de peças de substituição
não autorizadas.
As informações de segurança relativas a este produto destinam-se a profissionais destes serviços e não
devem ser utilizadas por outras pessoas.
Risco de choques eléctricos e ferimentos graves durante a desmontagem e manutenção deste produto.
Os profissionais destes serviços devem estar avisados deste facto e tomar os cuidados necessários.
CUIDADO: Quando vir este símbolo, existe a possível presença de uma potencial tensão
perigosa na zona do produto em que está a trabalhar. Antes de começar, desligue o produto da
tomada eléctrica ou seja cuidadoso caso o produto tenha de estar ligado à corrente eléctrica para
realizar a tarefa necessária.
xxii Service Manual
Informació de Seguretat
• La seguretat d'aquest producte es basa en l'avaluació i aprovació del disseny original i els components
•
•
•
específics.
El fabricant no es fa responsable de les qüestions de
seguretat si s'utilitzen peces de recanvi no autoritzades.
La informació pel manteniment d’aquest producte està orientada exclusivament a professionals i no està
destinada
a ningú que no ho sigui.
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, desendolleu l'equip o extremeu les precaucions si, per
treballar amb l'equip, l'heu de connectar.
Notices and safety information
xxiii
Preface
This manual contains maintenance procedures for service personnel. It is divided into the following chapters:
1. General information contains a general description of the printer and the maintenance approach used to
2.
3.
4.
5.
6.
7.
repair it. Special tools and test equipment, as well as general environmental and safety instructions, are
discussed.
Diagnostic information contains an error indicator table, symptom tables, and service checks used to
isolate failing field replaceable units (FRUs).
Diagnostic aids contains tests and checks used to locate or repeat symptoms of printer problems.
Repair information provides instructions for making printer adjustments and removing and installing
FRUs.
Connector locations uses illustrations to identify the connector locations and test points on the printer.
Preventive maintenance contains the lubrication specifications and recommendations to prevent
problems.
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 identifies something that might damage the product hardware or software.
There are several types of caution statements:
CAUTION
A caution identifies something that might cause a servicer harm.
CAUTION
This type of caution indicates there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the
product must receive power in order to perform the task.
CAUTION
This type of caution indicates a hot surface.
CAUTION
This type of caution indicates a tipping hazard.
xxiv Service Manual
1. General information
The Dell™ 5535dn printer is an All-In-One laser multi-functional printer (MFP) that provides print, copy, scan,
and fax functions designed to attach to most computer networks. The operator panel is touch-sensitive and
allows the user to adjust the viewing angle.
The following table shows the features available in the Dell 5535dn printer.
Machine
type
Description
AIO
Simplex
ADF
Duplex
ADF
Duplex
printer
7462-031
X651de
x
x
x
7462-035
X652de/
5535dn
x
x
x
7462-0A1
X654de
x
x
x
7462-0A5
X656dte
x
x
x
7462-231
X654de
x
x
x
7462-232
X654de
x
x
x
7462-235
X656dte
x
x
x
7462-236
X656dte
x
x
x
7462-2A1
X654de
x
x
x
7462-2A2
X654de
x
x
x
7462-2A5
X656dte
x
x
x
7462-2A6
X656dte
x
x
x
7462-432
X658de
x
x
x
7462-436
X658de
x
x
x
7462-4A2
X658de
x
x
x
7462-4A6
X658de
x
x
x
Modem
Hard drive
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Maintenance approach
The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the
service error codes, user status messages, user error messages, service checks, and diagnostic aids to
determine the MPF problem and repair the failure. After you complete the repair, perform tests as needed to
verify the repair. See “Start” on page 2-1.
General information
1-1
Printer overview
CAUTION: Do not set up this product or make any electrical or cabling connections, such as the
power cord or options and features, during a lightning storm.
Printer configuration
Note: Printer configuration may vary depending on your printer model.
Basic models
1
2
7
3
2
4
5
6
1
Automatic Document Feeder (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
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 www.dell.com.
1-2 Service Manual
Options
The following options are available. Some options are not available in every country or region. Contact your
point of purchase for options available in your country or region.
Available internal options
• Memory cards
– Printer memory
– Flash memory
– Fonts
• Firmware cards
– Bar Code and Forms
– IPDS and SCS/TNe
– PrintCryptionTM
– PRESCRIBE
• Printer hard disk
• LXK Internal Solutions Ports (ISP)
– RS-232-C Serial ISP
– Parallel 1284-B ISP
– 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
Duplex option—550-sheet
Output expander
High-capacity output stacker
StapleSmart™ Finisher
5-bin Mailbox
Vertical Kiosk Presenter
Horizontal Kiosk Presenter
General information
1-3
Supported paper sizes, types, and weights
The following tables provide information on standard and optional paper sources and the types of paper they
support.
Note: For an unlisted paper size, select the closest larger listed size.
Paper sizes supported by the printer
250-or 550-sheet
trays (standard
or optional
Paper size
Dimensions
A4
210 x 297 mm
(8.3 x 11.7 in.)
x
A5
148 x 210 mm
(5.8 x8.3in.)
x
A61,2
105 x 148 mm
(4.1 x 5.8 in.)
J15 B5
182 x 257 mm
(7.2 x 10.1 in.)
x
Letter
216 x 279 mm
(8.5 x 11 in.)
x
Legal
216 x 356 mm
(8.5 x14 in.)
x
Executive
184 x 267 mm
(7.3 x 10.5 in.)
Oficio1
Optional
2000-sheet
tray
x
Multipurpose
feeder
Duplex unit
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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
(2.8 x 5 in.) up
to
216 x 356 mm
(8.5 x 14 in.)
148 x 182 mm
(5.8 x 7.7 in.) up
to
216 x 356 mm
(8.5 x 14 in.)
x
x
x
7 3/4 Envelopes
(Monarch)
98 x 191 mm
(3.9 x 7.5 in.)
x
9 Envelope
98 x 225 mm
(3.9 x 8.9 in.)
x
10 Envelope
105 x 241 mm
(4.1 x 9.5 in.)
x
DL Envelope
110 x 220 mm
(4.3 x 8.7 in)
x
1-4 Service Manual
x
250-or 550-sheet
trays (standard
or optional
Paper size
Dimensions
Other Envelope
98 x 162 mm
(3.9 x 6.4 in.) to
176 x 250 mm
(6.9 x 9.8 in.)
Optional
2000-sheet
tray
Multipurpose
feeder
Duplex unit
x
1
This size appears in the Paper Size menu only when the paper source does not support size sensing or
when size sensing is turned off.
2
Only the standard exit bin supports this size.
3
This size setting formats the page for 216 x 356 mm (8.5 x 14 in.) 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 types and weights supported by the printer
Paper type
Paper
•
•
•
•
•
•
•
•
•
•
250-or 550-sheet
trays (standard or
optional
Optional 2000sheet tray
Multipurpose
feeder
Duplex unit
x
x
x
x
x
x
x
x
Plain
Bond
Colored
Custom
Letterhead
Light
Heavy
Preprinted
Rough/Cotton
Recycled
Card stock
Envelopes
1
Labels
x
x
x
x
x
x
x
x
x
• Paper
• Vinyl
Transparencies
1Printing
labels require a special label fuser cleaner which prevents duplexing. The label fuser cleaner is
included with the special cartridge required for label applications.
Paper types and weights supported by the output bins
Use this table to determine the possible output destinations of print jobs which use supported paper types and
weights. The paper capacity of each output bin is listed in parentheses. Paper capacity estimations are
calculated based on 75 g/m2 (20 lb) paper.
General information
1-5
The finisher supports 60-176 g/m2 (16-47 lb) paper weights.
Optional hardware
Paper type
Paper
Standard exit bin
(350 or 550 sheets)
Output
Expander (550
sheets) or High
Capacity
Output stacker
(1850 sheets)
x
x
x
x
Labels3
x
x
Transparencies
x
x
•
•
•
•
•
•
•
•
•
•
5-Bin Mailbox
(500 sheets)1
x
StapleSmart II
Finisher
(500 sheets)2
x
Plain
Bond
Colored
Custom
Letterhead
Light
Heavy
Preprinted
Rough/Cotton
Recycled
Card stock
Envelopes
1Supports
60-90 g/m2 (16-24 lb) paper weights.
2Maximum
of 50 sheets of 75 g/m2 (20 lb) paper per stapled packet. Results may vary with heavier
paper.
3Printing
labels require a special label fuser cleaner which prevents duplexing. The label fuser cleaner is
included with the special cartridge required for label applications.
1-6 Service Manual
Tools required for service
Flat-blade screwdrivers, various sizes
Phillips screwdrivers, various sizes
7/32 inch open-end wrench
7.0 mm nut driver
5.5 mm wrench
Needlenose pliers
Diagonal side cutters
Spring hook
Analog or digital multimeter
Flash light (optional)
General information
1-7
Acronyms
ADF
AIO
CCD
CRU
DIMM
DRAM
EP
EPROM
ESD
FRU
GB
HCIT
HVPS
ITC
LASER
LCD
LED
LES
LVPS
MDC
MFP
MPF
NVRAM
OPT
PC
PIN
PJL
POR
POST
PP
PWM
RIP
SCC
SDRAM
SIMM
UAT
USB
V ac
V dc
1-8 Service Manual
Automatic Document Feeder
All-In-One
Charge Coupled Device (CCD)
Customer Replaceable Unit
Dual Inline Memory Module
Dynamic Random Access Memory
Electrophotographic process
Erasable Programmable Read-Only Memory
Electrostatic Discharge
Field Replaceable Unit
Gigabyte
High-Capacity Input Tray
High Voltage Power Supply
Internal Tray Card
Light Amplification by Stimulated Emission of Radiation
Liquid Crystal Display
Light-Emitting Diode
LXK Embedded Solution (applications)
Low Voltage Power Supply
Motor Driver Control
Multifunction Printer
Multipurpose Feeder
Nonvolatile Random Access Memory
Optical Sensor
Photoconductor
Personal Identification Number
Printer Job Language
Power-On Reset
Power-On Self Test
Parts Packet
Pulse Width Modulation
Raster Imaging Processor
Scanner Control Card
Synchronous Dynamic Random Access Memory
Single Inline Memory Module
Universally Adjustable Tray
Universal Serial Bus
Volts alternating current
Volts direct current
2. Diagnostic information
Start
CAUTION:
Unplug the power cord from the electrical outlet before you connect or disconnect any cable
electronic board or assembly.
CAUTION:
If the printer is kept on, never touch the conductive parts if not specifically required. The power
switch and inlet of the low voltage power supply card (LVPS card) assembly is live even while
the power supply is cut off. Never touch the live parts.
CAUTION:
Be careful to avoid burns by safely handling hot parts.
CAUTION
The printer weight is greater than 18kg (40 lbs) and requires two or more trained personnel to
lift it safely. Use the hand holds on the side of the printer. Make sure your fingers are not
under the printer when you lift or set the printer down.
To determine the corrective action necessary to repair a printer, look for the following information:
• Does the POR stop? Check the [POR (Power On Reset) sequence]
• Do you have a symptom, rather than an error message?
• If you have an error message or user message, check the following:
– [Error tables]
– [2xx Paper Jams]
– [User attendance messages]
– [Service checks] for individual error messages
Note: There may be printer error messages that are not contained in this service manual. Call your next level
support for assistance.
Diagnostic information
2-1
Confirm the installation status
Be sure to check the following items before starting the troubleshooting procedures.
• With the power cord unplugged from the wall outlet, check that the cord is free from breakage, short-circuit,
disconnected wire, or incorrect connection in the power cord.
• The printer is properly grounded. Check the power cord ground terminal.
• The printer is not installed at a place subjected to extreme temperature, extreme humidity or rapid changes
in temperature.
• The printer is not installed close to water service, humidifier, heat generating unit, fire, in a very dusty
•
•
•
•
•
•
•
place, or a place exposed to air flow from the air conditioning system.
The printer is not installed in a place where volatile gas or inflammable gas 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 following is an example of the events that occur during the POR sequence:
1.
2.
3.
4.
5.
6.
7.
8.
Turn the machine on.
The Dell splash screen appears with a progress bar in the center until the code is loaded.
The fuser cooling fan turns on.
The fuser unit assembly lamps turn on.
The system card assembly cooling fan turns on.
Operator panel LED becomes solid.
The transport motor turns on.
Ready is displayed.
Entering Diagnostics Menu
1.
2.
3.
4.
Turn off the printer.
Press and hold 3 and 6 buttons simultaneously.
Turn on the printer.
Release the buttons after 10 seconds.
2-2 Service Manual
User attendance messages
Error
code or
message
Error contents
Description/Action
Possible repair actions
System
Timeout
System Timeout
The system detects a firmware
component that is no longer
responding.
Turn the power off; wait a few
seconds, and then turn the
power back on.
30.XX
Invalid Refill Change
Cartridge
Message is cleared when a
new print cartridge is installed.
Install the proper print
cartridge.
31.XX
Defective Cartridge
Error code 31 displays when
the top front cover is closed
and a defective print cartridge
is detected. It may take the
printer 10-20 seconds to
determine if the print cartridge
is defective.
1. Install the proper print
cartridge.
2. Ensure the print cartridge ID
connector assembly is properly
connected.
3. Replace the print cartridge
ID connector assembly if
problem remains. Go to “Print
cartridge ID connector
assembly removal” on
page 4-33.
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 printer does
not know the actual paper size
loaded in the tray. For autosize sensing trays, this error
occurs if the paper stop is in
the incorrect position. Make
sure the Paper Size setting is
correct for the size paper that is
being used.
1. Ensure the media tray
guides are properly set for the
media being used.
2. Ensure the Switch media
size is properly connected.
3. Replace the switch media
size if problem remains.
Go to “Switch (media size)
assembly removal” on
page 4-45.
4. Replace the media tray
assembly if problem remains.
Diagnostic information
2-3
Error
code or
message
35
Error contents
Res Save Off
Deficient Memory
Description/Action
Possible repair actions
This IR is displayed when the
printer lacks sufficient memory
to enable Resource Save. This
message usually indicates the
user has allocated too much
memory for one or more of the
printer's link buffers; however,
modification of other printer
settings which affect the
amount of available memory
may also create this condition.
If the user desires to enable
Resource Save after this
message has been posted, it is
recommended the user either
install additional memory or set
each link buffer back to the
Auto value.
This message displays when
the printer lacks sufficient
memory to enable Resource
Save. This message usually
indicates the user has
allocated too much memory for
one or more of the printer link
buffers; however, modification
of other printer settings which
affect the amount of available
memory may also create this
condition. If restoration of
Resource Save is required
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 when
Resource Save has been
enabled, and compare it to the
memory available when
Resource Save is disabled.
Once all link buffers are
returned to Auto, the user
should exit the menus to
activate the link buffer
changes. Once the printer
returns to the Ready state, the
user may then enable
Resource Save and then finally
go back and modify the link
buffers again. The user should
note the reduction of available
memory to the link buffers
when Resource Save has been
enabled as opposed to the
memory available when
Resource Save is disabled.
37A
2-4 Service Manual
Insufficient Collation
Area
This message displays when
the printer memory is
insufficient to perform the Flash
Memory Defragment operation.
Note: This message is posted
prior to the actual start of the
defragment operation. The
printer code determines if
enough printer memory is
available to complete the
defragment operation. The
user should not be concerned
with losing resources stored in
the flash option.
• Press
to disable
Resource Save and
continue printing.
To enable Resource Save
after you get this message:
- Make sure the link
buffers are set to Auto,
then exit the menus to
activate the link buffer
changes.
- When Ready is
displayed, enable
Resource Save.
• Install additional memory.
The following actions may be
taken:
• Press
to clear the
message. To perform the
defragment operation:
- Delete fonts, macros,
and other data in RAM.
- Install additional printer
memory.
• Press
until Busy/
Waiting appears. The
following actions are
available:
- Cancel Job
- Reset Printer
- Reset Active Bin
Error
code or
message
37C
Error contents
Insufficient Memory
Description/Action
This message displays when
the printer memory used to
restore the Print and Hold jobs
from the disk and found that
some or all of the jobs could
not be restored. The printer ran
out of memory while attempting
to restore the jobs.
Possible repair actions
The following actions may be
taken:
• Press
to clear the
message. Some of the Print
and Hold jobs on the disk
will not be restored. They
remain on the disk, but
cannot be accessed.
• Press
until Busy/
Waiting appears. The
following functions may be
available:
- Cancel Job
- Reset Printer
Reset Active Bin
38
Memory Full
This message displays when
the printer is processing an
incoming 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
This message displays when
the page is too complex to
print. The following actions
may be taken:
The following actions may be
taken:
• Press
to clear the
message and continue the
job. Some data loss may
occur. Simplify the print job
and reprint, if necessary.
• Press
until Busy/
Waiting appears. The
following selections are
possible:
- Cancel Job
- Reset Printer
Reset Active Bin
Diagnostic information
2-5
Error
code or
message
42.XY
Error contents
Cartridge Region
Mismatch
Description/Action
This IR is displayed when the
printer detects that the installed
cartridge has a region that
differs from the below options.
To clear this IR, the printer
cartridge must be replaced with
one that has a proper region.
Possible repair actions
Install a new toner cartridge
that matches the correct
regional specification.
X and Y can have the following
values:
0 : Worldwide region or
Undefined region
1 : America
2 : EMEA
3 : Asia
4 : Latin America
9 : Invalid region
50
PPDS Font Error
This message displays when
the PPDS interpreter has
encountered a font error.
Note: This error may only
occur when the printer is
formatting PPDS print data.
The following actions may be
taken:
• Press
to clear the
message and continue
processing the job.
• Press
until Busy/
Waiting appears. The
following are available:
- Cancel Job
- Reset Printer
- Reset Active Bin
51
Defective Flash
This message displays when
the printer detects 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 normal operation
continues. Flash operations
are not allowed until the flash is
formatted.
54A
Serial Option [x] Error
This IR is displayed when a
serial error (framing, parity or
overrun) has been detected on
the specified optional serial
port. This usually indicates that
the serial port has not been set
up correctly.
Go to network service check.
Once a host interface error has
been displayed for the first
time, reporting of further host
interface errors for the
associated port is suppressed
until the interface parameters
are changed for the
associated, or the machine is
powered off.
2-6 Service Manual
See “ADF & Scanner Related
Troubleshooting” on
page 2-171.
Error
code or
message
54B
54C
Error contents
Std Network Software
Error
Network [x] Software
Error
Description/Action
This error displays when a
network port is detected, but
the printer cannot establish
communications with it.
Possible repair actions
The following actions may be
taken:
• Press
to clear the
message and continue
printing.
The job may not print
correctly.
• Program new firmware for
the network interface.
Reset the printer.
This error displays when a
network port is detected, but
the printer cannot establish
communications with it.
The following actions may be
taken:
• Press
to clear the
message and continue
printing.
The job may not print
correctly.
• Program new firmware for
the network interface.
• Reset the printer.
55B
Unsupported Option
in Slot [x]
An unsupported option is
installed in the specified
solutions port. Power off the
printer and remove the
unsupported option in the
specified slot.
Remove unsupported option.
56A
Parallel Port [x]
Disabled
This error displays when data
is sent to the printer 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.
Serial Port [x]
Disabled
This error displays when data
is sent to the printer across an
serial port, but the port has
been disabled. Once this
message displays, reporting of
further errors is suppressed
until the menus are entered, or
the printer is reset.
Go to network service check.
Standard USB Port
Disabled
Displayed when status is
requested over the USB port,
but the port has been disabled.
Once the error has been
displayed for the first time,
reporting of further errors is
suppressed until the menus are
entered or the printer is reset.
The following actions may be
taken:
56B
56C
See “ADF & Scanner Related
Troubleshooting” on
page 2-171.
See “ADF & Scanner Related
Troubleshooting” on
page 2-171.
• Press
to clear the
message. The printer
discards any data received
on the USB port.
• Press
until Busy/
Waiting appears. The
following are available:
- Reset Printer
Reset Active Bin
Diagnostic information
2-7
Error
code or
message
56E
Error contents
Description/Action
USB Port [x] Disabled
Displayed when status is
requested over the USB port,
but the port has been disabled.
Once the error has been
displayed for the first time,
reporting of further errors is
suppressed until the menus are
entered or the printer is reset.
Possible repair actions
The following actions may be
taken:
• Press
to clear the
message. The printer
discards any data received
on the USB port.
• Press
until Busy/
Waiting appears. The
following are available:
- Reset Printer
Reset Active Bin
58A
Too Many Bins
Attached
This error code displays when
too many bins are attached to
the printer.
1. Turn off and unplug the
printer.
2. Remove the excess bins.
3. Plug in the printer, and turn
it on.
58B
Too Many Disks
Installed
This error code displays when
too many disks are attached to
the printer.
1. Turn off and unplug the
printer.
2. Remove the excess disks.
3. Plug in the printer, and turn
it on.
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.
1. Turn off and unplug the
printer.
2. Remove the excess flash
memory.
3. Plug in the printer, and turn
it on.
User can power off and remove
extra flash options.
58D
Too Many Trays
Attached
This error code displays when
too many input trays are
attached to the printer.
1. Turn off and unplug the
printer.
2. Remove the excess trays.
3. Plug in the printer, and turn
it on.
59A
Incompatible Duplex
An incompatible duplex option
is installed.
Remove the incompatible
duplex option 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
external duplex unit
assembly.
3. Plug in the printer, and turn
it on.
2-8 Service Manual
Error
code or
message
Error contents
Description/Action
Possible repair actions
59B
Incompatible
Envelope Feeder
An incompatible envelope
feeder is installed.
Remove the incompatible
feeder 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
envelope feeder.
3. Plug in the printer, and turn
it on.
59C
Incompatible Output
Bin [x]
An incompatible output bin is
installed. For Output Bin x, x=1,
2, or 3.
Remove the incompatible
output bin and press
to
clear the message.
Note: If the user installed the
incompatible device to satisfy a
Check Device Connections/
reattach message, the user
should reinstall an associated
compatible option or hot unplug
the option.
1. Turn off and unplug the
printer.
2. Remove the incompatible
output option.
3. Plug in the printer, and turn
it on.
59D
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 in the printer, and turn
it on.
61
Defective Disk
This error code displays when
the printer detects a defective
disk. This error may occur at
power on or during disk format
and write operations. While this
message displays.
press
to clear the
message. The disk is marked
defective and normal printer
operations continue. Disk
operations are not allowed with
a defective disk. The Format
Disk menu is not shown.
62
Disk Full
This error code displays when
there is not enough free space
on the disk to hold the
resources that have been
requested to be written to the
disk. This message displays for
both resource and PostScript
Disk operators when the disk is
full.
TBD
Diagnostic information
2-9
Error
code or
message
Error contents
Description/Action
80
Routine Maintenance
Needed
The operator panel displays
this message at each 300K
page count interval. It is
necessary to replace the fuser
assembly, transfer roller,
charge roll, and pick rolls at this
interval to maintain the print
quality and reliability of the
printer. The parts are available
as a maintenance kit. For more
information, go to “Scheduled
maintenance” on page 6-2.
Scheduled maintenance
required.
Refer to chapter 6.
Go to “Preventive
maintenance” on page 6-1.
88A
Cartridge Low
This IR is displayed when
cartridge low occurs and the
cartridge low alarm is
activated. If cartridge alarm is
not activated, this is not an
intervention condition.
Replace the print cartridge.
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 displayed when toner
cartridge is exhausted/empty.
Replace the print cartridge.
2-10 Service Manual
Possible repair actions
Error code table
Error
code or
message
200.00
Error contents
Sensor (input) area
jam
Description/Action
The media is jammed in the
sensor (input) area.
Possible repair actions
1. Fan the media and check for
obstructions.
2. Go to sensor (input) service
check.
See “Sensor (input) service
check” on page 2-107.
200.01
Sensor (input)
lingering jam
Source = MPF, duplex
or envelope feeder
The media reached the sensor
(input) but did not clear it within
the specified time.
1. Fan the media and check for
obstructions.
2. Go to sensor (input)
lingering jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
200.02
Sensor (input)
lingering jam
The media reached the sensor
(input) but did not clear it within
the specified time.
1. Fan the media and ensure it
is properly installed.
2. Go to sensor (input)
lingering jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
200.04
Sensor (input) early
jam
The media reached the sensor
(input) sooner than the
specified time.
Wrong config ID causes engine
to assume 500 paper path on
250 model.
200.06
200.07
Sensor (input) early
jam
Sensor (input) late
jam
Source = input option
tray
200.08
Sensor (input) early
jam
1. Fan the media and ensure it
is properly installed.
2. Go to sensor (input) early
jam service check.
See “Sensor (input) early jam
service check” on
page 2-130.
The sensor (input) rebounded
once the trailing edge of the
media passed.
Go to sensor (input) service
check.
The media is late reaching the
sensor (input) within the
specified time.
Go to sensor (input) late jam
service check.
The media reaches the sensor
(input) sooner than the
specified time.
See “Sensor (input) service
check” on page 2-107.
See “Sensor (input) late jam
service check” on
page 2-127.
1. Fan the media and ensure it
is properly installed.
2. Go to sensor (input) early
jam service check.
See “Sensor (input) early jam
service check” on
page 2-130.
Diagnostic information
2-11
Error
code or
message
Error contents
Description/Action
Possible repair actions
200.09
Printhead laser start
failure
The printhead laser start
process failed because it did
not receive proper feedback
signal from the printhead
motor.
1. Check all connections on
the printhead.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
200.10
Printhead motor
synchronization error
The printhead motor is not
synchronized when media
reaches the sensor (input).
1. Remove all media present
in media path.
2. Check all connections on
the printhead.
3. Check all connections on
the system card assembly.
4. Replace the printhead if
problem remains. Go to
“Printhead assembly
removal” on page 4-34.
200.11
Printhead polygon
mirror synchronization
error
The printhead polygon mirror
motor becomes unsynchronized when the media
reaches the sensor (input).
1. Remove all media present
in media path.
2. Check all connections on
the printhead.
3. Check all connections on
the system card assembly.
4. Replace the printhead if
problem remains. Go to
“Printhead assembly
removal” on page 4-34.
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
“Printhead assembly
removal” on page 4-34.
4. Replace the system card if
problem remains. Go to
“System card assembly
removal” on page 4-50.
200.13
200.14
2-12 Service Manual
Sensor (input) static
jam
Sensor (input) early
jam
Media remains on the sensor
(input) during the warm up
sequence.
The media reached the sensor
(input) sooner than the
specified time.
Go to sensor (input) static jam
service check.
See “Sensor (input) static
jam service check” on
page 2-131.
Go to sensor (input) early jam
service check.
See “Sensor (input) early jam
service check” on
page 2-130.
Error
code or
message
200.15
Error contents
Laser power did not
settle
Description/Action
Laser circuit failure on
printhead or system card
assembly.
Possible repair actions
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
“Printhead assembly
removal” on page 4-34.
4. Replace the system card if
problem remains. Go to
“System card assembly
removal” on page 4-50.
200.16
Main drive motor
assembly load error
The main drive motor assembly
has failed or caused high
mechanical load due to paper
jam or bind.
200.17
Sensor (input)
lingering jam
The media reached the sensor
(input) but did not clear it within
the specified time.
Source = Tray 1
Tray level= Not Low
200.18
Sensor (input)
lingering jam
Source = Tray 1
Tray level = Low
200.19
Sensor (input)
lingering jam
Source = Tray 1
Tray level = Empty
200.27
Sensor (input)
lingering jam
Source = Tray 2
Tray level = Not Low
200.28
Sensor (input)
lingering jam
Source = Tray 2
Tray level = Low
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
1. Remove all media present
in media path.
2. Check all connections on
the main drive motor
assembly.
3. Check all connections on
the system card assembly.
4. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Diagnostic information
2-13
Error
code or
message
200.29
Error contents
Sensor (input)
lingering jam
Source = Tray 2
Tray level = Empty
200.32
Operator panel door
assembly
switch failure
200.33
Sensor (input) early
jam
Description/Action
The media reached the sensor
(input) but did not clear it within
the specified time.
200.37
Sensor (toner empty)
failure
Sensor (input)
lingering jam
Source = Tray 3
Tray level= Not Low
200.38
Sensor (input)
lingering jam
Source = Tray 3
Tray level = Low
200.39
Sensor (input)
lingering jam
Source = Tray 3
Tray level = Empty
200.47
Sensor (input)
lingering jam
Source = Tray 4
Tray level = Not Low
2-14 Service Manual
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Operator panel door assembly
not fully closed. Interlock
switch not functioning correctly.
1. Ensure that the operator
panel door assembly is fully
closed.
2. Check operator panel door
assembly for damage.
3. Check interlock switch (in
left operator panel hinge)
for damage.
4. Check all connections on
the system card assembly.
The media reached the sensor
(input) sooner than the
specified time.
1. Fan the media and ensure it
is properly installed.
Wrong config ID causes engine
to assume 500 paper path on
250 model.
200.34
Possible repair actions
2. Go to sensor (input) early
jam service check.
See “Sensor (input) early jam
service check” on
page 2-130.
The sensor (toner empty) has
failed or is not sensing the
pulse wheel on the print
cartridge.
1. Inspect print cartridge pulse
wheel for damage and replace
if needed.
The media reached the sensor
(input) but did not clear it within
the specified time.
Go to sensor (input) lingering
jam service check.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
2. Check the sensor (toner
empty) for proper operation.
See “Sensor (ADF sheet
through) static jam service
check” on page 2-112.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Error
code or
message
200.48
Error contents
Sensor (input)
lingering jam
Source = Tray 4
Tray level = Low
200.49
Sensor (input)
lingering jam
Source = Tray 4
Tray level = Empty
200.57
Sensor (input)
lingering jam
Source = Tray 5
Tray level = Not Low
200.58
Sensor (input)
lingering jam
Source = Tray 5
Tray level = Low
200.59
Sensor (input)
lingering jam
Source = Tray 5
Tray level = Empty
201.00
Sensor (fuser output)
area jam.
Description/Action
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media reached the sensor
(input) but did not clear it within
the specified time.
The media is jammed in the
sensor (fuser output) area.
Type 1 fuser
201.01
Main drive motor
assembly load error.
Type 1 fuser
201.02
Sensor (fuser output)
late jam.
Type 1 fuser
Possible repair actions
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (input) lingering
jam service check.
See “Sensor (input) lingering
jam service check” on
page 2-129.
Go to sensor (fuser output)
service check.
See “Sensor (fuser output)
service check” on
page 2-107.
The main drive motor assembly
has failed or caused high
mechanical load due to paper
jam or bind.
1. Check all connections on
the main drive motor
assembly.
2. Check all connections on
the system card assembly.
3. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
The media is late reaching the
sensor (fuser output) within the
specified time.
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
If problem remains, a type 2
fuser can be installed.
201.04
Sensor (narrow
media) late jam
Type 1 fuser
The expected wide media is
late reaching the sensor
(narrow media) within the
specified time.
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
Diagnostic information
2-15
Error
code or
message
201.06
Error contents
Sensor (narrow
media) late jam
Type 1 fuser
201.07
Sensor (fuser output)
late jam
Type 1 fuser
201.25
Sensor (fuser output)
area jam.
Description/Action
The expected wide media is
late reaching the sensor
(narrow media) within the
specified time.
Main drive motor
assembly load error.
Type 2 fuser
201.27
Sensor (fuser output)
late jam.
Type 2 fuser
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
The media is late reaching the
sensor (fuser output) within the
specified time.
Go to sensor (fuser output) late
jam service check.
The media is jammed in the
sensor (fuser output) area.
Go to sensor (fuser output)
service check.
Type 2 fuser
201.26
Possible repair actions
See “Sensor (fuser output)
late jam service check” on
page 2-132.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
The main drive motor assembly
has failed or caused high
mechanical load due to paper
jam or bind.
1. Check all connections on
the main drive motor
assembly.
2. Check all connections on
the system card assembly.
3. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
The media is late reaching the
sensor (fuser output) within the
specified time.
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
If problem remains, a type 2
fuser can be installed.
201.29
Sensor (narrow
media) late jam
Type 2 fuser
201.30
Operator panel door
assembly interlock
switch failure
Type 2 fuser
2-16 Service Manual
The expected wide media is
late reaching the sensor
(narrow media) within the
specified time.
The printer detected that the
operator panel door interlock
switch did not cycle prior to
printer restart.
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
1. Remove all media present
in media path.
2. Ensure that the operator
panel door assembly is fully
open then fully closed.
3. Check operator panel door
assembly for damage.
4. Check interlock switch (in
left operator panel hinge)
for damage.
5. Check all connections on
the system card assembly.
Error
code or
message
201.31
Error contents
Sensor (narrow
media) late jam
Type 2 fuser
201.32
Sensor (fuser output)
late jam
Type 2 fuser
201.50
Sensor (fuser output)
late jam
Type 1 fuser
Description/Action
The expected wide media is
late reaching the sensor
(narrow media) within the
specified time.
The media is late reaching the
sensor (fuser output) within the
specified time.
The media is late reaching the
sensor (fuser output) within the
specified time.
Fuser page count has
exceeded life.
201.51
Main drive motor
assembly load error.
Type 1 fuser
Sensor (fuser output)
late jam
Type 1 fuser
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
Go to sensor (fuser output)
service check.
See “Sensor (fuser output)
service check” on
page 2-107.
The main drive motor assembly
has failed or caused high
mechanical load due to paper
jam or bind.
1. Check all connections on
the main drive motor
assembly.
2. Check all connections on
the system card assembly.
3. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
The media is late reaching the
sensor (fuser output) within the
specified time.
Go to sensor (fuser output) late
jam service check.
Fuser page count has
exceeded life.
201.52
Possible repair actions
Fuser page count has
exceeded life.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
If problem remains, a type 2
fuser can be installed.
201.54
Sensor (narrow
media) late jam
Type 1 fuser
The media is late reaching the
sensor (narrow media) within
the specified time.
Fuser page count has
exceeded life
201.55
Operator panel door
assembly interlock
switch open failure
Type 1 fuser
Fuser page count has
exceeded life
The printer detected that the
switch (operator panel door
interlock) did not cycle prior to
printer restart.
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
1. Remove all media present
in media path.
2. Ensure that the operator
panel door assembly is fully
open then fully closed.
3. Check operator panel door
assembly for damage.
4. Check interlock switch (in
left operator panel hinge)
for damage.
5. Check all connections on
the system card assembly.
Diagnostic information
2-17
Error
code or
message
201.56
Error contents
Sensor (narrow
media) late jam
Type 1 fuser
Description/Action
The media is late reaching the
sensor (narrow media) within
the specified time.
Fuser page count has
exceeded life.
201.57
Sensor (fuser output)
late jam
Type 1 fuser
The media is late reaching the
sensor (fuser output) within the
specified time.
Fuser page count has
exceeded life
201.75
Sensor (fuser output)
late jam
Type 2 fuser
The media is late reaching the
sensor (fuser output) within the
specified time.
Fuser page count has
exceeded life.
201.76
Main drive motor
assembly load error.
Type 2 fuser
Sensor (fuser output)
late jam
Type 2 fuser
Sensor (narrow
media) late jam
Type 2 fuser
Operator panel door
assembly interlock
switch open failure
Type 2 fuser
Fuser page count has
exceeded life
2-18 Service Manual
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
The media is late reaching the
sensor (fuser output) within the
specified time.
Go to sensor (fuser output) late
jam service check.
The media is late reaching the
sensor (narrow media) within
the specified time.
Fuser page count has
exceeded life
201.80
See “Sensor (narrow media)
late jam service check” on
page 2-135.
1. Remove all media present
in media path.
2. Check all connections on
the main drive motor
assembly.
3. Check all connections on
the system card assembly.
4. Replace the main drive
motor assembly if problem
remains. Go to “Main drive
motor assembly removal”
on page 4-20.
Fuser page count has
exceeded life.
201.79
Go to sensor (narrow media)
late jam service check.
The main drive motor assembly
has failed or caused high
mechanical load due to paper
jam or bind.
Fuser page count has
exceeded life.
201.77
Possible repair actions
The printer detected that the
switch (operator panel door
interlock) did not cycle prior to
printer restart.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
1. Remove all media present
in media path.
2. Ensure that the operator
panel door assembly is fully
open then fully closed.
3. Check operator panel door
assembly for damage.
4. Check interlock switch (in
left operator panel hinge)
for damage.
5. Check all connections on
the system card assembly.
Error
code or
message
201.81
Error contents
Sensor (narrow
media) late jam
Type 2 fuser
Description/Action
The media is late reaching the
sensor (narrow media) within
the specified time.
Fuser page count has
exceeded life.
201.82
Sensor (fuser output)
late jam
Type 2 fuser
The media is late reaching the
sensor (fuser output) within the
specified time.
Fuser page count has
exceeded life
202.00
Paper jam around
fuser exit or redrive
area.
Page may be jammed in fuser
exit or redrive area.
Type 1 fuser
202.01
Sensor (fuser output)
lingering jam.
Destination is
standard bin.
202.02
Media did not reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Sensor (narrow
media) static jam
Type 1 fuser
202.04
Sensor (fuser output)
bounce
Type 1 fuser
202.06
and
Type 1 fuser
Type 1 fuser
202.03
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Sensor (fuser output)
static jam
Type 1 fuser
Media remains on the sensor
(narrow media) during the
warm up sequence.
The sensor (fuser output)
rebounded once the trailing
edge of the media passed.
Media remains on the sensor
(fuser output) during the warm
up sequence.
Possible repair actions
Go to sensor (narrow media)
late jam service check.
See “Sensor (narrow media)
late jam service check” on
page 2-135.
Go to sensor (fuser output) late
jam service check.
See “Sensor (fuser output)
late jam service check” on
page 2-132.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Go to sensor (fuser output)
service check. See
“Sensor (fuser output)
service check” on
page 2-107.
5. Go to sensor (narrow
media) service check. See
“Sensor (narrow media)
service check” on
page 2-108.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (narrow media)
static jam service check.
See “Sensor (narrow media)
static jam service check” on
page 2-136.
Go to sensor (fuser output)
service check.
See “Sensor (fuser output)
service check” on
page 2-107.
Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser output)
static jam service check” on
page 2-135.
Diagnostic information
2-19
Error
code or
message
202.07
Error contents
Description/Action
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Type 1 fuser
202.09
Sensor (fuser output)
lingering jam.
Type 1 fuser
202.10
Sensor (fuser output)
lingering jam.
Destination is output
option.
202.11
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Type 1 fuser
Media did reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Type 1 fuser
Media did reach the sensor
(narrow media)
Sensor (fuser output)
static jam
Media remains on the sensor
(fuser output) and the sensor
(narrow media) during the
warm up sequence.
and
Sensor (narrow
media) static jam
Type 1 fuser
2-20 Service Manual
and
Media did not reach the sensor
(narrow media)
Destination is output
option.
202.13
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Type 1 fuser
Destination is
standard bin.
202.12
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Possible repair actions
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
1. Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser
output) static jam service
check” on page 2-135.
2. Go to sensor (narrow
media) static jam service
check. See “Sensor
(narrow media) static jam
service check” on
page 2-136.
Error
code or
message
202.25
Error contents
Paper jam around
fuser exit or redrive
area.
Description/Action
Possible repair actions
Page may be jammed in fuser
exit or redrive area.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Go to sensor (fuser output)
service check.
5. See “Sensor (fuser
output) service check” on
page 2-107.
6. Go to sensor (narrow
media) service check. See
“Sensor (narrow media)
service check” on
page 2-108.
Type 2 fuser
202.26
Sensor (fuser output)
lingering jam.
Destination is
standard bin.
202.27
Media did not reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Sensor (narrow
media) static jam
Type 2 fuser
202.29
Sensor (fuser output)
bounce
Type 2 fuser
202.30
and
Type 2 fuser
Type 2 fuser
202.28
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Media remains on the sensor
(narrow media) during the
warm up sequence.
The sensor (fuser output)
rebounded once the trailing
edge of the media passed.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (narrow media)
static jam service check.
See “Sensor (narrow media)
static jam service check” on
page 2-136.
Go to sensor (fuser output)
service check.
See “Sensor (fuser output)
service check” on
page 2-107.
Never sent the divert
command to the
stacker.
Type 2 fuser
202.31
Sensor (fuser output)
static jam
Type 2 fuser
202.32
Sensor (fuser output)
lingering jam.
Type 2 fuser
Media remains on the sensor
(fuser output) during the warm
up sequence.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser output)
static jam service check” on
page 2-135.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Diagnostic information
2-21
Error
code or
message
202.34
Error contents
Description/Action
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Type 2 fuser
202.35
Sensor (fuser output)
lingering jam.
Destination is output
option.
202.36
Media did not reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Type 2 fuser
Media did reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Destination is output
option.
202.38
and
Type 2 fuser
Destination is
standard bin.
202.37
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Media did reach the sensor
(narrow media)
Sensor (fuser output)
static jam
Media remains on the sensor
(fuser output) and the sensor
(narrow media) during the
warm up sequence.
1. Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser
output) static jam service
check” on page 2-135.
2. Go to sensor (narrow
media) static jam service
check. See “Sensor
(narrow media) static jam
service check” on
page 2-136.
Page may be jammed in fuser
exit or redrive area.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Go to sensor (fuser output)
service check. See
“Sensor (fuser output)
service check” on
page 2-107.
5. Go to sensor (narrow
media) service check. See
“Sensor (narrow media)
service check” on
page 2-108.
Sensor (narrow
media) static jam
Type 2 fuser
Paper jam around
fuser exit or redrive
area.
Type 1 fuser
Fuser page count has
exceeded life
2-22 Service Manual
Go to sensor (fuser output)
lingering jam service check.
Type 2 fuser
and
202.50
Possible repair actions
Error
code or
message
202.51
Error contents
Description/Action
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Go to sensor (fuser output)
lingering jam service check.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Go to sensor (fuser output)
lingering jam service check.
Media remains on the sensor
(narrow media) during the
warm up sequence.
Go to sensor (narrow media)
static jam service check.
Destination is
standard bin.
Type 1 fuser
Possible repair actions
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Fuser page count has
exceeded life.
202.52
Sensor (fuser output)
lingering jam.
Type 1 fuser
Fuser page count has
exceeded life.
202.53
Sensor (narrow
media) static jam
Type 1 fuser
Fuser page count has
exceeded life.
202.54
Sensor (fuser output)
bounce
Type 1 fuser
The sensor (fuser output)
rebounded once the trailing
edge of the media passed.
Fuser page count has
exceeded life.
202.56
Sensor (fuser output)
static jam
Type 1 fuser
Sensor (fuser output)
lingering jam.
Type 1 fuser
Sensor (fuser output)
lingering jam.
Type 1 fuser
Sensor (fuser output)
lingering jam.
Destination is output
option.
Type 1 fuser
Fuser page count has
exceeded life.
See “Sensor (fuser output)
service check” on
page 2-107.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Go to sensor (fuser output)
lingering jam service check.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Fuser page count has
exceeded life.
202.60
Go to sensor (fuser output)
service check.
Go to sensor (fuser output)
static jam service check.
Fuser page count has
exceeded life.
202.59
See “Sensor (narrow media)
static jam service check” on
page 2-136.
Media remains on the sensor
(fuser output) during the warm
up sequence.
Fuser page count has
exceeded life.
202.57
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Media did not reach the sensor
(narrow media)
See “Sensor (fuser output)
static jam service check” on
page 2-135.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Diagnostic information
2-23
Error
code or
message
202.61
Error contents
Description/Action
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Destination is
standard bin.
Type 1 fuser
Fuser page count has
exceeded life.
202.62
Sensor (fuser output)
lingering jam.
Destination is output
option.
Type 1 fuser
Fuser page count has
exceeded life.
202.63
Sensor (fuser output)
static jam
and
and
Media did reach the sensor
(narrow media)
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Media did reach the sensor
(narrow media)
Fuser page count has
exceeded life.
202.77
and
Type 2 fuser
Media did not reach the sensor
(narrow media)
Sensor (fuser output)
lingering jam.
Type 2 fuser
Fuser page count has
exceeded life.
2-24 Service Manual
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Destination is
standard bin.
Fuser page count has
exceeded life.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Go to sensor (fuser output)
service check. See
“Sensor (fuser output)
service check” on
page 2-107.
5. Go to sensor (narrow
media) service check. See
“Sensor (narrow media)
service check” on
page 2-108.
Type 2 fuser
Sensor (fuser output)
lingering jam.
Go to sensor (fuser output)
lingering jam service check.
Page may be jammed in fuser
exit or redrive area.
Type 1 fuser
202.76
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
1. Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser
output) static jam service
check” on page 2-135.
2. Go to sensor (narrow
media) static jam service
check. See “Sensor
(narrow media) static jam
service check” on
page 2-136.
Fuser page count has
exceeded life.
Paper jam around
fuser exit or redrive
area.
Go to sensor (fuser output)
lingering jam service check.
Media remains on the sensor
(fuser output) and the sensor
(narrow media) during the
warm up sequence.
Sensor (narrow
media) static jam
202.75
Possible repair actions
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Error
code or
message
202.78
Error contents
Sensor (narrow
media) static jam
Type 2 fuser
Description/Action
Media remains on the sensor
(narrow media) during the
warm up sequence.
Fuser page count has
exceeded life.
202.79
Sensor (fuser output)
bounce
Type 2 fuser
The sensor (fuser output)
rebounded once the trailing
edge of the media passed.
Fuser page count has
exceeded life.
202.81
Sensor (fuser output)
static jam
Type 2 fuser
Media remains on the sensor
(fuser output) during the warm
up sequence.
Fuser page count has
exceeded life.
202.82
Sensor (fuser output)
lingering jam.
Type 2 fuser
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Fuser page count has
exceeded life.
202.84
Sensor (fuser output)
lingering jam.
Type 2 fuser
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Fuser page count has
exceeded life.
202.85
Sensor (fuser output)
lingering jam.
Destination is output
option.
Type 2 fuser
Fuser page count has
exceeded life.
202.86
Sensor (fuser output)
lingering jam.
Destination is
standard bin.
Type 2 fuser
Fuser page count has
exceeded life.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Media did not reach the sensor
(narrow media)
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
and
Media did reach the sensor
(narrow media)
Possible repair actions
1. Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser
output) static jam service
check” on page 2-135.
2. Go to sensor (narrow
media) static jam service
check. See “Sensor
(narrow media) static jam
service check” on
page 2-136.
Go to sensor (fuser output)
service check.
See “Sensor (fuser output)
service check” on
page 2-107.
Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser output)
static jam service check” on
page 2-135.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
Diagnostic information
2-25
Error
code or
message
202.87
Error contents
Description/Action
Sensor (fuser output)
lingering jam.
Media reached the sensor
(fuser output) but did not clear
it in the specified time.
Destination is output
option.
Type 2 fuser
Fuser page count has
exceeded life.
202.88
Sensor (fuser output)
static jam
and
and
Media did reach the sensor
(narrow media)
Media remains on the sensor
(fuser output) and the sensor
(narrow media) during the
warm up sequence.
Sensor (narrow
media) static jam
Type 2 fuser
Fuser page count has
exceeded life.
202.99
Fuser ID chip failure
The system does not recognize
the ID chip on the fuser unit.
Possible repair actions
Go to sensor (fuser output)
lingering jam service check.
See “Sensor (fuser output)
lingering jam service check”
on page 2-133.
1. Go to sensor (fuser output)
static jam service check.
See “Sensor (fuser
output) static jam service
check” on page 2-135.
2. Go to sensor (narrow
media) static jam service
check. See “Sensor
(narrow media) static jam
service check” on
page 2-136.
Replace the fuser unit
assembly.
Go to “Fuser unit assembly
removal” on page 4-15.
203.00
Paper jam around
redrive area.
Page may be jammed in
redrive area.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Go to sensor (fuser output)
service check. See
“Sensor (fuser output)
service check” on
page 2-107.
5. Go to sensor (narrow
media) service check. See
“Sensor (narrow media)
service check” on
page 2-108.
203.01
Internal duplex drive
motor control failure.
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 connections on
the system card assembly.
4. Replace the duplex media
entrance drive motor
assembly if problem
remains. Go to “Duplex
drive motor assembly
removal” on page 4-9.
Internal duplex
2-26 Service Manual
Error
code or
message
Error contents
Description/Action
Possible repair actions
203.08
Redrive motor load
error
The redrive motor assembly
has failed or caused high
mechanical load during the
warm up sequence.
1. Remove all media present
in media path.
2. Ensure that upper redive
assembly is properly
installed.
3. Check all connections on
the redrive motor
assembly.
4. Check all connections on
the system card assembly.
5. Replace the redrive motor
assembly if problem
remains. Go to “Redrive
motor assembly removal”
on page 4-38.
203.10
Redrive motor control
failure.
The redrive motor does not
reach the proper operating
speed at the specified time.
1. Remove all media present
in media path.
2. Ensure that upper redive
assembly is properly
installed.
3. Check all connections on
the redrive motor
assembly.
4. Check all connections on
the system card assembly.
5. Replace the redrive motor
assembly if problem
remains. Go to “Redrive
motor assembly removal”
on page 4-38.
Media tray 1
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
remains. Go to “Redrive
motor assembly removal”
on page 4-38.
203.20
Redrive motor lost
encoder failure
The redrive motor is not
reporting pulses back to the
engine.
1. Check all connections on
the redrive motor
assembly.
2. Check all connections on
the system card assembly.
3. Replace the redrive motor
assembly if problem
remains. Go to “Redrive
motor assembly removal”
on page 4-38.
Diagnostic information
2-27
Error
code or
message
230.00
Error contents
Paper jam around
internal duplex.
Description/Action
Page may be jammed in
internal duplex area.
Source = Internal
duplex
230.01
Sensor (duplex input)
lingering jam
Source = Internal
duplex
230.02
Sensor (duplex input)
late jam
Source = Internal
duplex
230.03
Sensor (duplex input)
bounce
Source = Internal
duplex
230.04
Sensor (input) late
jam from duplex
Source = Internal
duplex
230.05
sensor (duplex input)
lingering jam
Source = Internal
duplex
230.06
Sensor (input) late
jam from duplex
Source = Internal
duplex
230.07
Sensor (input) late
jam from duplex
Source = Internal
duplex
2-28 Service Manual
Media reached the sensor
(duplex input) but did not clear
it in the specified time.
Media is late reaching the
sensor (duplex input) within the
specified time.
Possible repair actions
1. Remove all media present
in media path.
2. Check for obstructions in
media path.
3. Go to sensor (fuser output)
service check. See
“Sensor (fuser output)
service check” on
page 2-107.
4. Go to sensor (duplex input)
service check. See
“Sensor (duplex input)
service check” on
page 2-108.
Go to sensor (duplex input)
lingering jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (duplex input) late
jam service check.
See “Sensor (duplex input)
late jam service check” on
page 2-137.
The sensor (duplex input)
rebounded once the trailing
edge of the media passed.
Go to sensor (duplex input)
service check. See “Sensor
(duplex input) service
check” on page 2-108.
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.
Media reached the sensor
(duplex input) but did not clear
it in the specified time.
Media is late reaching the
sensor (input) within the
specified time during the
second side printing using the
internal duplex.
Media is late reaching the
sensor (input) within the
specified time during the
second side printing using the
internal duplex.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (duplex input)
lingering jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Error
code or
message
230.08
Error contents
Internal duplex drive
motor load error
Source = Internal
duplex
230.10
Internal duplex drive
motor control failure.
Source = Internal
duplex
230.13
sensor (duplex input)
static jam
Source = Internal
duplex
230.14
Paper jam around
internal duplex.
Description/Action
Possible repair actions
The internal duplex drive motor
assembly has failed or caused
high mechanical load during
warm up sequence.
1. Remove all media present
in media path.
2. Check all connections on
the duplex media entrance
drive motor assembly.
3. Check all connections on
the system card assembly.
4. Replace the duplex drive
motor assembly if problem
remains. Go to “Duplex
drive motor assembly
removal” on page 4-9.
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 connections on
the system card assembly.
4. Replace the duplex media
entrance drive motor
assembly if problem
remains. Go to “Duplex
drive motor assembly
removal” on page 4-9.
Media remains on the sensor
(duplex input) during the warm
up sequence.
Internal duplex drive
motor assembly
underspeed error.
Source = Internal
duplex
See “Sensor (duplex input)
lingering jam service check”
on page 2-139.
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
“Sensor (fuser output)
service check” on
page 2-107.
4. Go to sensor (duplex input)
service check. See
“Sensor (duplex input)
service check” on
page 2-108.
The internal duplex drive motor
does not rotate at the specified
speed.
1. Remove all media present
in media path.
2. Check all connections on
the duplex media entrance
drive motor assembly.
3. Check all connections on
the system card assembly.
4. Replace the duplex media
entrance drive motor
assembly if problem
remains. Go to “Duplex
drive motor assembly
removal” on page 4-9.
Source = Internal
duplex
230.18
Go to sensor (duplex input)
static jam service check.
Diagnostic information
2-29
Error
code or
message
230.20
Error contents
Internal duplex drive
motor lost encoder
failure
Description/Action
Possible repair actions
The internal duplex drive motor
is not reporting pulses back to
the engine.
1. Remove all media present
in media path.
2. Check all connections on
the duplex media entrance
drive motor assembly.
3. Check all connections on
the system card assembly.
4. Replace the duplex drive
motor assembly if problem
remains. Go to “Duplex
drive motor assembly
removal” on page 4-9.
Media is late reaching the
sensor (duplex input) within the
specified time.
Go to sensor (duplex input) late
jam service check.
Source = Internal
duplex
231.00
Sensor (duplex input)
late jam
Source = External
duplex
232.00
Sensor (duplex input)
lingering jam
Source = External
duplex
233.00
Sensor (duplex
double-feed) late jam
Source = External
duplex
2-30 Service Manual
Media reached the sensor
(duplex input) but did not clear
it in the specified time.
Media is late reaching the
sensor (duplex double-feed)
within the specified time.
See “Sensor (duplex input)
late jam service check” on
page 2-137.
Go to sensor (duplex input)
lingering jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
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
external duplex is fully
closed.
5. Check all connections on
the external duplex
assembly.
6. Replace the external
duplex assembly if problem
remains.
Error
code or
message
234.00
Error contents
Sensor (duplex exit)
late jam
Source = External
duplex
235.00
Sensor (duplex
double-feed) lingering
jam
Source = External
duplex
236.00
Sensor (duplex exit)
lingering jam
Source = External
duplex
237.00
Sensor (input) late
jam from duplex
Source = External
duplex
Description/Action
Possible repair actions
Media is late reaching the
sensor (duplex exit) within the
specified time.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check sensor (duplex exit)
for proper operation. See
“Sensor (duplex exit)
service check (external
duplex only)” on
page 2-109.
7. Check all connections on
the external duplex
assembly.
8. Replace the external
duplex assembly if problem
remains.
Media reached the sensor
(duplex double-feed) 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 path.
4. Ensure the external duplex
assembly is properly
installed.
5. Replace the external
duplex assembly if problem
remains.
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 path.
4. Ensure the external duplex
assembly is properly
installed.
5. Check sensor (duplex exit)
for proper operation.See
“Sensor (duplex exit)
service check (external
duplex only)” on
page 2-109.
6. Replace the external
duplex assembly if problem
remains.
Media is late reaching the
sensor (input) within the
specified time during the
second side printing using the
external duplex.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Diagnostic information
2-31
Error
code or
message
237.07
Error contents
Paper jam around
external duplex
Description/Action
Page may be jammed in
external duplex area.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Ensure the external duplex
tray is fully closed.
7. Ensure the media tray 1 is
fully closed.
8. Check the lower option
drive (PTO) assembly for
damage.
9. Check all connections on
the external duplex
assembly.
10.Replace the external
duplex assembly if problem
remains.
Media remains on a sensor
within the external duplex
assembly during the warm up
sequence.
1. Remove all media present
in media path.
2. Replace the external
duplex assembly if problem
remains.
Source = External
duplex.
238.00
External duplex
sensor static jam
Source = External
duplex
238.01
Sensor (duplex input)
static jam
Source = External
duplex
238.02
Sensor (duplex exit)
static jam
Source = External
duplex
238.03
Sensor (duplex input)
static jam
Sensor (duplex exit)
static jam
Source = External
duplex
2-32 Service Manual
Possible repair actions
Media remains on the sensor
(duplex input) during the warm
up sequence.
Media remains on the sensor
(duplex exit) during the warm
up sequence.
Media remains on the sensor
(duplex input) and the sensor
(duplex exit) during the warm
up sequence.
Go to sensor (duplex input)
static jam service check.
See “Sensor (duplex input)
lingering jam service check”
on page 2-139.
1. Remove all media present
in media path.
2. Go to sensor (duplex exit)
service check. See
“Sensor (duplex exit)
service check (external
duplex only)” on
page 2-109.
3. Replace the external
duplex assembly if problem
remains.
Go to sensor (duplex input)
static jam service check.
See “Sensor (duplex input)
lingering jam service check”
on page 2-139.
Error
code or
message
238.04
Error contents
Sensor (duplex
double-feed) static
jam
Description/Action
Possible repair actions
Media remains on the sensor
(duplex double-feed) during the
warm up sequence.
1. Remove all media present
in media path.
2. Replace the external
duplex assembly if problem
remains.
Media remains on the sensor
(duplex input) and the sensor
(double-feed) during the warm
up sequence.
1. Remove all media present in
media path.
Source = External
duplex
238.05
Sensor (duplex input)
static jam
Sensor (double-feed)
static jam
Source = External
duplex
238.06
Sensor (duplex exit)
static jam
Sensor (double-feed)
static jam
See “Sensor (duplex input)
lingering jam service check”
on page 2-139.
Media remains on the sensor
(duplex exit) and the sensor
(double-feed) during the warm
up sequence.
Source = External
duplex
238.07
Sensor (duplex input)
static jam
Sensor (double-feed)
static jam
2. Go to sensor (duplex input)
static jam service check.
Media remains on the sensor
(duplex input), sensor (doublefeed) and the sensor (duplex
exit) during the warm up
sequence.
Sensor (duplex exit)
1. Remove all media present
in media path.
2. Go to sensor (duplex exit)
service check. See
“Sensor (duplex exit)
service check (external
duplex only)” on
page 2-109.
3. Replace the external
duplex assembly if problem
remains.
Go to sensor (duplex input)
static jam service check.
See “Sensor (duplex input)
lingering jam service check”
on page 2-139.
Source = External
duplex
239.00
Mechanical feed error
or timing error.
Source = External
duplex
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check sensor (duplex
input) for proper operation.
See “Sensor (duplex
input) service check” on
page 2-108.
3. Check sensor (duplex exit)
for proper operation. See
“Sensor (duplex exit)
service check (external
duplex only)” on
page 2-109.
4. Replace the external
duplex assembly if problem
remains.
Diagnostic information
2-33
Error
code or
message
239.01
Error contents
External duplex
assembly error
Description/Action
Possible repair actions
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Source = External
duplex
239.02
External duplex
assembly error
Source = External
duplex
239.03
Device controls
response error.
Source = External
duplex
2-34 Service Manual
Error
code or
message
239.04
Error contents
Input device ready
response error.
Description/Action
Possible repair actions
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Source = External
duplex
239.05
Output device
response error.
Source = External
duplex
239.06
Failed the last page of
a staple job.
Source = External
duplex
Diagnostic information
2-35
Error
code or
message
239.07
Error contents
Select output device
error.
Description/Action
Possible repair actions
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Mechanical feed error or timing
error.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
4. Ensure the external duplex
assembly is properly
installed.
5. Ensure the rear door of the
external duplex is fully
closed.
6. Check all connections on
the external duplex
assembly.
7. Replace the external
duplex assembly if problem
remains.
Source = External
duplex
239.08
Input source ready
error.
Source = External
duplex
239.11
Sensor (input) late
jam from duplex
Source = External
duplex
241.00
Media tray 1 area jam
Source = Tray 1
2-36 Service Manual
Media is late reaching the
sensor (input) within the
specified time during the
second side printing using the
external duplex.
The media is jammed in the
media tray 1 area.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
Error
code or
message
241.01
Error contents
Pick motor control
failure.
Media tray 1
241.06
Sensor (input) late
jam
Source = Tray 1 or
MPF
241.07
Pick motor load error
Source = Media tray 1
Description/Action
Possible repair actions
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The media is late reaching the
sensor (input) within the
specified time.
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Diagnostic information
2-37
Error
code or
message
241.08
Error contents
Pick motor load error
Source = Media tray 1
241.10
Sensor (input) late
jam
Source = Tray 1
241.11
Sensor (input) late
jam
Source = Tray 1
241.12
Sensor (input) late
jam
Source = Tray 1 or
envelope feeder
241.14
Sensor (input) late
jam
Source = Tray 1 or
envelope feeder
241.15
Sensor (input) late
jam
Source = Tray 1 or
envelope feeder
241.16
Sensor (input) late
jam
Source = Tray 1
2-38 Service Manual
Description/Action
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
Possible repair actions
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Error
code or
message
241.18
Error contents
Sensor (input) late
jam
Source = Tray 1
241.19
Pick motor control
failure.
Source = Tray 1
241.20
Tray 1 pick motor lost
encoder failure
Description/Action
The media is late reaching the
sensor (input) within the
specified time.
Media tray 2 area jam
Source = Tray 2
242.02
Sensor (pass through)
late jam
Source = Tray 2
242.03
Sensor (pass through)
late jam
Source = Tray 2
242.04
Sensor (pass through)
late jam
Source = Tray 2
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor is not reporting
pulses back to the engine.
1. Check all connections on
the pick arm assembly.
2. Check all connections on
the system card assembly.
3. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
The media is jammed in the
media tray 2 area.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
Source = Tray 1
242.00
Possible repair actions
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Diagnostic information
2-39
Error
code or
message
242.05
Error contents
Description/Action
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 2
242.06
Sensor (pass through)
late jam
Source = Tray 2
242.08
Sensor (pass through)
lingering jam
Source = Tray 2
242.09
Sensor (input) late
jam
Source = Tray 2
242.10
sensor (pass through)
late jam
Source = Tray 2
242.13
Sensor (pass through)
static jam
Source = Tray 2
242.16
sensor (pass through)
late jam
Source = Tray 2
242.17
Media tray pulled jam
Source = Tray 2
242.18
Pick retry timeout
Source = Tray 2
242.19
Pick retry timeout
Source = Tray 2
2-40 Service Manual
The media is late reaching the
sensor (pass through) within
the specified time.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Possible repair actions
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
The engine timed out waiting
for the tray 2 to report ready
before the first pick attempt.
Turn the machine off/on.
The engine timed out waiting
for the tray 2 to report ready
before a pick retry attempt.
Turn the machine off/on.
Error
code or
message
242.52
Error contents
Tray 2 pick motor
overrun failure
Source = Tray 2
242.33
Tray 2 not ready
Source = Tray 2
242.34
Empty tray pick
attempted
Description/Action
Possible repair actions
The Pick motor encoder
continues to detect pulses after
the motor was turned off.
1. Check all connections on
the pick arm assembly.
2. Check all connections on
the system card assembly.
3. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
Tray was not properly pushed
into the machine.
1. Check the size sensing
fingers on the media tray
for damage
2. Replace the media tray
assembly if problem
remains.
3. Check the switch (media
size) for proper connection.
4. Replace the switch (media
size) if problem remains.
Go to “Switch (media
size) assembly removal”
on page 4-45.
The pick arm attempted to pick
with no media in the tray.
1. Check the media out
actuator for damage.
2. Replace the media out
actuator if problem
remains. Go to “Media out
actuator removal” on
page 4-23.
Source = Tray 2
242.36
Sensor (pass through)
static jam
Source = Tray 2
242.37
Sensor (pass through)
late jam
Source = Tray 2
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
242.39
Media tray pulled jam
A media tray above the source
tray was pulled during the
printing process.
242.40
Sensor (pass through)
lingering jam
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
Source = Tray 2
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Diagnostic information
2-41
Error
code or
message
242.49
Error contents
HCIT tray lift motor
stalled failure
Source = Tray 2
Description/Action
The HCIT tray lift motor has
stalled or has become
obstructed.
Possible repair actions
1. Ensure the HCIT media tray
assembly is properly inserted
into the machine.
2. Check the HCIT tray lift
motor assembly for binding or
damage.
3. Replace the HCIT tray lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
242.50
HCIT tray lift motor
underspeed failure
Source = Tray 2
The HCIT tray lift motor does
not rotate at the specified
speed.
1. Ensure the HCIT media tray
assembly is properly inserted
into the machine.
2. Check the HCIT tray lift drive
motor assembly for binding or
damage.
3. Replace the HCIT tray lift
motor assembly if problem
remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
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 lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
2-42 Service Manual
Error
code or
message
242.65
242.66
Error contents
Pick motor load error
Description/Action
Source = Media tray 2
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor
underspeed failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 2
242.67
Possible repair actions
Pick motor overspeed
failure
Source = Media tray 2
Diagnostic information
2-43
Error
code or
message
242.68
Error contents
Description/Action
Possible repair actions
Pick motor stop error
Pick motor stop error detected
by options tray x
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
Source = Media tray 2
242.69
Pick motor control
failure.
Source = Media tray 2
243.00
Media tray 3 area jam
The media is jammed in the
media tray 3 area.
243.02
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 3
243.03
Sensor (pass through)
late jam
Source = Tray 3
243.04
Sensor (pass through)
late jam
Source = Tray 3
2-44 Service Manual
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Error
code or
message
243.05
Error contents
Description/Action
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 3
243.06
Sensor (pass through)
late jam
Source = Tray 3
243.08
Sensor (pass through)
lingering jam
Source = Tray 3
243.10
Sensor (pass through)
late jam
Source = Tray 3
243.13
Sensor (pass through)
static jam
Source = Tray 3
243.16
Sensor (pass through)
late jam
Source = Tray 3
243.17
Media tray pulled jam
Source = Tray 3
243.18
Pick retry timeout
Source = Tray 3
243.19
Pick retry timeout
Source = Tray 3
243.33
Tray 3 not ready
Source = Tray 3
The media is late reaching the
sensor (pass through) within
the specified time.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Possible repair actions
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
The engine timed out waiting
for the tray 3 to report ready
before the first pick attempt.
Turn the machine off/on.
The engine timed out waiting
for the tray 3 to report ready
before a pick retry attempt.
Turn the machine off/on.
Tray was not properly pushed
into the machine.
1. Check the size sensing
fingers on the media tray
for damage
2. Replace the media tray
assembly if problem
remains.
3. Check the switch (media
size) for proper connection.
4. Replace the switch (media
size) if problem remains.
Go to “Switch (media
size) assembly removal”
on page 4-45.
Diagnostic information
2-45
Error
code or
message
243.34
Error contents
Empty tray pick
attempted
Description/Action
Possible repair actions
The pick arm attempted to pick
with no media in the tray.
1. Check the media out
actuator for damage.
2. Replace the media out
actuator if problem
remains. Go to “Media out
actuator removal” on
page 4-23.
Source = Tray 3
243.36
Sensor (pass through)
static jam
Source = Tray 3
243.37
Sensor (pass through)
late jam
Source = Tray 3
243.39
Media tray pulled jam
Source = Tray 3
243.40
Sensor (pass through)
lingering jam
Source = Tray 3
243.49
HCIT tray lift motor
stalled failure
Source = Tray 3
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The HCIT tray lift motor has
stalled or has become
obstructed.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
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.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
243.50
HCIT tray lift motor
underspeed failure
Source = Tray 3
The HCIT tray lift motor does
not rotate at the specified
speed.
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.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
2-46 Service Manual
Error
code or
message
243.52
Error contents
HCIT tray lift motor
overrun failure
Source = Tray 3
Description/Action
Possible repair actions
The HCIT tray lift motor
continues to detect pulses after
the motor has turned off.
1. Ensure the HCIT media tray
assembly is properly inserted
into the machine.
2. Check the HCIT tray lift
motor assembly for binding or
damage.
3. Replace the HCIT tray lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
243.65
243.66
Pick motor load error
Source = Media tray 3
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor
underspeed failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 3
Diagnostic information
2-47
Error
code or
message
243.67
Error contents
Description/Action
Possible repair actions
Pick motor overspeed
failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor stop error detected
by options tray x
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 3
243.68
Pick motor stop error
Source = Media tray 3
243.69
Pick motor control
failure.
Source = Media tray 3
2-48 Service Manual
Error
code or
message
Error contents
Description/Action
244.00
Media tray 4 area jam
The media is jammed in the
media tray 4 area.
244.02
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 4
244.03
Sensor (pass through)
late jam
Source = Tray 4
244.04
Sensor (pass through)
late jam
Source = Tray 4
244.05
Sensor (pass through)
late jam
Source = Tray 4
244.06
Sensor (pass through)
late jam
Source = Tray 4
244.08
Sensor (pass through)
lingering jam
Source = Tray 4
244.10
Sensor (pass through)
late jam
Source = Tray 4
244.13
Sensor (pass through)
static jam
Source = Tray 4
244.16
Sensor (pass through)
late jam
Source = Tray 4
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
Possible repair actions
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Diagnostic information
2-49
Error
code or
message
Error contents
Description/Action
Possible repair actions
244.17
Media tray pulled jam
A media tray above the source
tray was pulled during the
printing process.
1. Remove all media present
in media path.
2. Close all media trays.
244.18
Pick retry timeout
The engine timed out waiting
for the tray 4 to report ready
before the first pick attempt.
Turn the machine off/on.
The engine timed out waiting
for the tray 4 to report ready
before a pick retry attempt.
Turn the machine off/on.
Source = Tray 4
244.19
Pick retry timeout
Source = Tray 4
244.33
Tray 4 not ready
Source = Tray 4
244.34
Empty tray pick
attempted
Tray was not properly pushed
into the machine.
1. Check the size sensing
fingers on the media tray
for damage
2. Replace the media tray
assembly if problem
remains.
3. Check the switch (media
size) for proper connection.
4. Replace the switch (media
size) if problem remains.
Go to “Switch (media
size) assembly removal”
on page 4-45.
The pick arm attempted to pick
with no media in the tray.
1. Check the media out
actuator for damage.
2. Replace the media out
actuator if problem
remains. Go to “Media out
actuator removal” on
page 4-23.
Source = Tray 4
244.36
Sensor (pass through)
static jam
Source = Tray 4
244.37
Sensor (pass through)
late jam
Source = Tray 4
244.39
Media tray pulled jam
Source = Tray 4
244.40
Sensor (pass through)
lingering jam
Source = Tray 4
2-50 Service Manual
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Error
code or
message
244.49
Error contents
HCIT tray lift motor
stalled failure
Source = Tray 4
Description/Action
The HCIT tray lift motor has
stalled or has become
obstructed.
Possible repair actions
1. Ensure the HCIT media tray
assembly is properly inserted
into the machine.
2. Check the HCIT tray lift
motor assembly for binding or
damage.
3. Replace the HCIT tray lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
244.50
HCIT tray lift motor
underspeed failure
Source = Tray 4
The HCIT tray lift motor does
not rotate at the specified
speed.
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.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
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 tray lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
Diagnostic information
2-51
Error
code or
message
244.65
244.66
Error contents
Pick motor load error
Description/Action
Source = Media tray 4
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor
underspeed failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 4
244.67
Pick motor overspeed
failure
Source = Media tray 4
2-52 Service Manual
Possible repair actions
Error
code or
message
244.68
Error contents
Description/Action
Possible repair actions
Pick motor stop error
Pick motor stop error detected
by options tray x
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
1. Remove all media present
in media path.
2. Check media for proper
installation.
3. Check for obstructions in
media path.
Source = Media tray 4
244.69
Pick motor control
failure.
Source = Media tray 4
245.00
Media tray 5 area jam
The media is jammed in the
media tray 5 area.
245.02
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 5
245.03
Sensor (pass through)
late jam
Source = Tray 5
245.04
Sensor (pass through)
late jam
Source = Tray 5
The media is late reaching the
sensor (pass through) within
the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Diagnostic information
2-53
Error
code or
message
245.05
Error contents
Description/Action
Sensor (pass through)
late jam
The media is late reaching the
sensor (pass through) within
the specified time.
Source = Tray 5
245.06
Sensor (pass through)
late jam
Source = Tray 5
245.08
Sensor (pass through)
lingering jam
Source = Tray 5
245.10
Sensor (pass through)
late jam
Source = Tray 5
245.13
Sensor (pass through)
static jam
Source = Tray 5
245.16
Sensor (pass through)
late jam
Source = Tray 5
245.17
Media tray pulled jam
Source = Tray 5
245.18
Pick retry timeout
Source = Tray 5
245.19
Pick retry timeout
Source = Tray 5
245.33
Tray 5 not ready
Source = Tray 5
2-54 Service Manual
The media is late reaching the
sensor (pass through) within
the specified time.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The media is late reaching the
sensor (pass through) within
the specified time.
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Possible repair actions
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
The engine timed out waiting
for the tray 5 to report ready
before the first pick attempt.
Turn the machine off/on.
The engine timed out waiting
for the tray 5 to report ready
before a pick retry attempt.
Turn the machine off/on.
Tray was not properly pushed
into the machine.
1. Check the size sensing
fingers on the media tray
for damage
2. Replace the media tray
assembly if problem
remains.
3. Check the switch (media
size) for proper connection.
4. Replace the switch (media
size) if problem remains.
Go to “Switch (media
size) assembly removal”
on page 4-45.
Error
code or
message
245.34
Error contents
Empty tray pick
attempted
Description/Action
Possible repair actions
The pick arm attempted to pick
with no media in the tray.
1. Check the media out
actuator for damage.
2. Replace the media out
actuator if problem
remains. Go to “Media out
actuator removal” on
page 4-23.
Source = Tray 5
345.36
Sensor (pass through)
static jam
Source = Tray 5
245.37
Sensor (pass through)
late jam
Source = Tray 5
245.39
Media tray pulled jam
Source = Tray 5
245.40
Sensor (pass through)
lingering jam
Source = Tray 5
245.49
HCIT tray lift motor
stalled failure
Source = Tray 5
Media remains on the sensor
(input) during the warm up
sequence.
The media is late reaching the
sensor (pass through) within
the specified time.
A media tray above the source
tray was pulled during the
printing process.
Media reached the sensor
(pass through) within the
specified time but did not clear
it within the specified time.
The HCIT tray lift motor has
stalled or has become
obstructed.
Go to sensor (pass through)
static jam service check.
See “Sensor (pass through)
static jam service check” on
page 2-143.
Go to sensor (pass through)
late jam service check.
See “Sensor (pass through)
late jam service check” on
page 2-141.
1. Remove all media present
in media path.
2. Close all media trays.
Go to sensor (pass through)
lingering jam service check.
See “Sensor (pass through)
lingering jam service check”
on page 2-142.
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.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
245.50
HCIT tray lift motor
underspeed failure
Source = Tray 5
The HCIT tray lift motor does
not rotate at the specified
speed.
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.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
Diagnostic information
2-55
Error
code or
message
245.52
Error contents
HCIT tray lift motor
overrun failure
Source = Tray 5
Description/Action
Possible repair actions
The HCIT tray lift motor
continues to detect pulses after
the motor has turned off.
1. Ensure the HCIT media tray
assembly is properly inserted
into the machine.
2. Check the HCIT tray lift
motor assembly for binding or
damage.
3. Replace the HCIT tray lift
drive motor assembly if
problem remains.
Go to “High capacity input
tray (HCIT) tray lift drive
motor assembly removal” on
page 4-167.
245.65
245.66
Pick motor load error
Source = Media tray 5
The pick motor has failed or
caused high mechanical load
due to paper jam or bind.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check, clean or replace the
pick rolls for wear and
excess contamination. Go
to “Pick roll assembly
removal” on page 4-31.
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
remains. Go to “Pick arm
assembly removal” on
page 4-29.
7. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor
underspeed failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 5
2-56 Service Manual
Error
code or
message
245.67
Error contents
Description/Action
Possible repair actions
Pick motor overspeed
failure
The pick motor does not rotate
at the specified speed.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Pick motor stop error detected
by options tray x
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The pick motor does not reach
the proper operating speed at
the specified time.
1. Remove all media present
in media path.
2. Ensure media tray is not
overfilled.
3. Check all connections on
the pick arm assembly.
4. Check all connections on
the system card assembly.
5. Replace the pick arm
assembly if problem
remains. Go to “Pick arm
assembly removal” on
page 4-29.
6. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Source = Media tray 5
245.68
Pick motor stop error
Source = Media tray 5
245.69
Pick motor control
failure.
Source = Media tray 5
250.00
MPF area jam
Source = MPF
The media is jammed in the
MPF area.
Go to sensor (input) service
check.
See “Sensor (input) service
check” on page 2-107.
Diagnostic information
2-57
Error
code or
message
250.03
Error contents
Sensor (input) late
jam
Source = MPF
250.06
Sensor (input) late
jam
Source = MPF
250.07
Sensor (input) late
jam
Source = MPF
250.08
Sensor (input) late
jam
Source = MPF
250.09
Sensor (input) late
jam
Source = MPF
250.10
Sensor (input) late
jam
Source = MPF
250.11
Sensor (input) late
jam
Source = MPF
260.00
2-58 Service Manual
Envelope feeder area
jam
Description/Action
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is jammed in the
envelope feeder area.
Possible repair actions
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Check media for proper
installation.
4. Check for obstructions in
media path.
5. Go to sensor (input) service
check. See “Sensor
(input) service check” on
page 2-107.
Error
code or
message
Error contents
Description/Action
Possible repair actions
260.01
Envelope feeder
assembly error
Mechanical feed error or timing
error.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Check media for proper
installation.
4. Check for obstructions in
media path.
5. Ensure the envelope feeder
assembly is properly
installed.
6. Check all connections on
the envelope feeder
assembly.
7. Replace the envelope
feeder assembly if problem
remains.
260.02
Envelope feeder
assembly error
Mechanical feed error or timing
error.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Check media for proper
installation.
4. Check for obstructions in
media path.
5. Ensure the envelope feeder
assembly is properly
installed.
6. Check all connections on
the envelope feeder
assembly.
7. Replace the envelope
feeder assembly if problem
remains.
260.05
Sensor (envelope
feeder pass through)
lingering jam
The media reached the sensor
(envelope feeder pass through)
but did not clear it in the
specified time.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Check for obstructions in
media path.
4. Ensure the envelope feeder
assembly is properly
installed.
5. Check all connections on
the envelope feeder
assembly.
6. Replace the envelope
feeder assembly if problem
remains.
Source = Envelope
feeder
Diagnostic information
2-59
Error
code or
message
260.06
Error contents
Sensor (envelope
feeder pass through)
late jam
Source = Envelope
feeder
260.07
Sensor (input) late
jam
Source = Envelope
feeder
260.10
Sensor (input) late
jam
Source = Envelope
feeder
260.11
Sensor (input) late
jam
Source = Envelope
feeder
260.12
Sensor (input) late
jam
Source = Envelope
feeder
Description/Action
Possible repair actions
The media is late reaching the
sensor (envelope feeder pass
through) within the specified
time.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Ensure envelope feeder is
not overfilled.
4. Check, clean or replace the
envelope feeder pick roll for
wear and excess
contamination.
5. Check all connections on
the envelope feeder.
6. Check all connections on
the system card assembly.
7. Replace the envelope
feeder assembly if problem
remains.
8. Replace system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
260.13
sensor (envelope
feeder pass through)
static jam
Media remains on the sensor
(envelope feeder pass through)
during the warm up sequence.
260.14
Sensor (input) late
jam
The media is late reaching the
sensor (input) within the
specified time.
Source = Envelope
feeder
2-60 Service Manual
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
1. Remove the envelope
feeder.
2. Remove all media present
in media path.
3. Replace the envelope
feeder is problem remains.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Error
code or
message
260.15
Error contents
Sensor (input) late
jam
Source = Envelope
feeder
260.16
Sensor (input) late
jam
Source = Envelope
feeder
271.03
x = bin
number
Sensor (output pass
through) lingering jam
Applies to:
Description/Action
The media is late reaching the
sensor (input) within the
specified time.
The media is late reaching the
sensor (input) within the
specified time.
Possible repair actions
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
Go to sensor (input) late jam
service check.
See “Sensor (input) late jam
service check” on
page 2-127.
The media reached the sensor
(output pass through) but did
not clear it in the specified time.
See “Sensor (output pass
through) lingering jam
service check” on
page 2-146.
The media is late reaching the
sensor (output pass through)
within the specified time.
See “Sensor (output pass
through) late jam service
check” on page 2-145.
The media reached the sensor
(output pass through) but did
not clear it in the specified time.
See “Sensor (output pass
through) lingering jam
service check” on
page 2-146.
Media remains on the sensor
(output pass through) during
the warm up sequence.
See “Sensor (output pass
through) static jam service
check” on page 2-146.
Media remains on the sensor
(mailbox empty) during the
warm up sequence.
See “Sensor (mailbox empty)
static jam service check” on
page 2-148.
High capacity output
Output expander
271.04
x = bin
number
Sensor (output pass
through) late jam
Applies to:
High capacity output
Output expander
271.05
x = bin
number
Sensor (output pass
through) lingering jam
Applies to:
High capacity output
Output expander
27x.14
x = bin
number
Sensor (output pass
through) static jam
Applies to:
High capacity stacker
Mailbox
Offset stacker
Output expander
Sensor (mailbox
empty) static jam
Applies to:
Mailbox
Diagnostic information
2-61
Error
code or
message
27x.15
x = bin
number
Error contents
Sensor (output pass
through) static jam
Applies to:
High capacity stacker
Mailbox
Description/Action
Possible repair actions
Media remains on the sensor
(output pass through) during
the warm up sequence.
See “Sensor (output pass
through) static jam service
check” on page 2-146.
Media remains on the sensor
(mailbox empty) during the
warm up sequence.
See “Sensor (mailbox empty)
static jam service check” on
page 2-148.
The media reached the sensor
(output pass through) but did
not clear it in the specified time.
See “Sensor (output pass
through) lingering jam
service check” on
page 2-146.
The media reached the sensor
(output pass through) but did
not clear it in the specified time.
See “Sensor (output pass
through) lingering jam
service check” on
page 2-146.
The sensor (left tamper HP)
does not detect that the tamper
has moved from home position.
1. Check all the connections on
the output option controller
card.
Offset stacker
Output expander
Sensor (mailbox
empty) static jam
Applies to:
Mailbox
27x.29
x = bin
number
Sensor (output pass
through) lingering jam
Applies to:
Offset stacker
Mailbox
Output expander
High capacity stacker
27x.50
x = bin
number
Sensor (output pass
through) lingering jam
Applies to:
Mailbox
27x.50
x = bin
number
Left tamper does not
leave home position
failure
Applies to:
2. Check the tamper drive belt
for damage and replace if
needed.
Offset stacker
3. Replace the left tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
27x.51
x = bin
number
Sensor (output pass
through) late jam
Applies to:
Mailbox
2-62 Service Manual
The media is late reaching the
sensor (output pass through)
within the specified time.
See “Sensor (output pass
through) late jam service
check” on page 2-145.
Error
code or
message
27x.51
x = bin
number
Error contents
Description/Action
Possible repair actions
Right tamper does not
leave home position
failure
The sensor (right tamper HP)
does not detect that the tamper
has moved from home position.
1. Check all the connections on
the output option controller
card.
Applies to:
2. Check the tamper drive belt
for damage and replace if
needed.
Offset stacker
3. Replace the right tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
271.52
x = bin
number
Sensor (mailbox
empty) lingering jam
Applies to:
The media reached the sensor
(mailbox empty) but did not
clear it in the specified time.
See “Sensor (mailbox empty)
lingering jam service check”
on page 2-147.
The media is late reaching the
sensor (mailbox empty) within
the specified time.
See “Sensor (mailbox empty)
late jam service check” on
page 2-147.
The media reached the sensor
(output pass through) but did
not clear it in the specified time.
See “Sensor (output pass
through) lingering jam
service check” on
page 2-146.
The media reached the sensor
(mailbox empty) but did not
clear it in the specified time.
See “Sensor (mailbox empty)
lingering jam service check”
on page 2-147.
The media is late reaching the
sensor (output pass through)
within the specified time.
See “Sensor (output pass
through) late jam service
check” on page 2-145.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
Mailbox
27x.53
x = bin
number
Sensor (mailbox
empty) late jam
Applies to:
Mailbox
27x.54
x = bin
number
Sensor (output pass
through) lingering jam
Applies to:
Mailbox
27x.55
x = bin
number
Sensor (mailbox
empty) lingering jam
Applies to:
Mailbox
27x.58
x = bin
number
Sensor (output pass
through) late jam
Applies to:
Mailbox
High capacity stacker
Offset stacker
Output expander
28x.25
x = bin
number
Invalid ejector motor
manager status.
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
Diagnostic information
2-63
Error
code or
message
28x.26
x = bin
number
Error contents
Description/Action
Possible repair actions
Timer 0 overflow (1ms
timer did not get
serviced for an entire
1ms)
A software failure has occurred
with the output option.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
The media reached the sensor
(stapler pass through) but did
not clear it in the specified time.
See “Sensor (stapler pass
through) lingering jam
service check” on
page 2-144.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
The output option transport
motor encoder is not detected
upon startup.
1. Check all connections on the
output option controller card.
2. Replace the output option if
problem remains.
Applies to:
StapleSmart finisher
28x.27
x = bin
number
Invalid paddle motor
manager status.
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.28
x = bin
number
Invalid main motor
manager state
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.29
x = bin
number
Sensor (stapler pass
through) lingering jam
Applies to:
StapleSmart finisher
28x.30
x = bin
number
Page ID complete not
clear
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.31
x = bin
number
Transport motor
encoder not detected
Applies to:
StapleSmart finisher
28x.32
x = bin
number
Transport motor
encoder not detected
Applies to:
The transport motor encoder
detection is lost during normal
operation.
1. Check all connections on the
output option controller card.
The transport motor rotate at
the specified speed
1. Check all connections on the
output option controller card.
StapleSmart finisher
28x.33
x = bin
number
Transport motor
overspeed failure
Applies to:
x = bin
number
Transport motor
underspeed failure
Applies to:
StapleSmart finisher
2-64 Service Manual
2. Replace the output option if
problem remains.
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.34
2. Replace the output option if
problem remains.
The transport motor rotate at
the specified speed
1. Check all connections on the
output option controller card.
2. Replace the output option if
problem remains.
Error
code or
message
28x.35
x = bin
number
Error contents
Sensor (self priming)
late failure
Applies to:
Description/Action
Possible repair actions
The sensor (self priming) within
the stapler assembly does not
detect a ready staple in the
specified time.
1. Check all the connections on
the output option controller
card and the stapler assembly.
StapleSmart finisher
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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.36
x = bin
number
Stapler drive motor
jammed
Applies to:
The stapler assembly has
jammed while stapling or the
stapler drive motor has 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.
StapleSmart finisher
3. Remove the stapler
assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.37
x = bin
number
Invalid tamper motor
manager status
Applies to:
A software failure has occurred
with the output option.
1. Turn the machine off/on.
2. Replace the output option if
problem remains.
StapleSmart finisher
Diagnostic information
2-65
Error
code or
message
28x.38
x = bin
number
Error contents
Staple ready home
position jam
Applies to:
StapleSmart finisher
Description/Action
Possible repair actions
The sensor (self priming) within
the stapler assembly does not
detect a ready staple in the
specified time after the staple
job was sent.
1. Check all the connections on
the controller card and the
stapler assembly.
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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.39
x = bin
number
Staple ready home
position jam
Applies to:
StapleSmart 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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 unit assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
2-66 Service Manual
Error
code or
message
28x.40
x = bin
number
Error contents
Left tamper does not
leave home position
failure
Description/Action
Possible repair actions
The sensor (left tamper HP)
does not detect that the tamper
has moved from home position.
1. Check all the connections on
the output option controller
card.
Applies to:
2. Check the tamper drive belt
for damage and replace if
needed.
StapleSmart finisher
3. Replace the left tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
28x.41
x = bin
number
Left tamper does not
move to home
position failure.
Applies to:
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.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
Diagnostic information
2-67
Error
code or
message
28x.42
x = bin
number
Error contents
Description/Action
Possible repair actions
Right tamper does not
leave home position
failure
The sensor (right tamper HP)
does not detect that the tamper
has moved from home position.
1. Check all the connections on
the output option controller
card.
Applies to:
2. Check the tamper drive belt
for damage and replace if
needed.
StapleSmart finisher
3. Replace the right tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
28x.43
x = bin
number
Right tamper does not
move to home
position failure.
The sensor (right tamper HP)
does not detect that the tamper
has reached home position.
1. Check all the connections on
the output option controller
card.
2. Check the tamper drive belt
for damage and replace if
needed.
Applies to:
StapleSmart finisher
3. Replace the right tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
28x.44
x = bin
number
Eject home position
jam
Applies to:
The sensor (eject HP) does not
detect that the eject
mechanism is operating.
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.45
x = bin
number
Eject home position
jam
Applies to:
StapleSmart finisher
2-68 Service Manual
1. Check all the connections on
the output option controller
card.
The sensor (eject HP) does not
detect the home position upon
completion of normal media
eject operation.
1. Check all the connections on
the output option controller
card.
2. Replace the output option if
problem remains.
Error
code or
message
28x.46
x = bin
number
Error contents
Paddle home position
jam
Applies to:
Description/Action
The sensor (paddle HP) does
not detect that the paddle is
operating.
Possible repair actions
1. Check all the connections on
the output option controller
card.
2. Check the sensor (paddle
HP) for damage and replace if
needed.
StapleSmart finisher
Go to “MFP stapler assembly
sensor (paddle HP) removal”
on page 4-215.
3. Replace the output option if
problem remains.
28x.47
x = bin
number
Paddle home position
jam
Applies to:
The sensor (paddle HP) does
not detect the home position
upon completion of normal
paddle operation.
StapleSmart finisher
1. Check all the connections on
the output option controller
card.
2. Check the sensor (paddle
HP) for damage and replace if
needed.
Go to “MFP stapler assembly
sensor (paddle HP) removal”
on page 4-215.
3. Replace the output option if
problem remains.
28x.48
x = bin
number
Deflector gate
transition to output
option not detected
Applies to:
The sensor (deflector gate HP)
does not detect transition of the
deflector gate to the output
option.
StapleSmart finisher
1. Check all the connections on
the output option controller
card.
2. Check the sensor (deflector
HP) for damage and replace if
needed.
Go to “MFP stapler assembly
sensor (deflector HP)
removal” on page 4-220.
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 (deflector gate HP)
does not detect transition of the
deflector gate to the standard
bin.
1. Check all the connections on
the output option controller
card.
2. Check the sensor (deflector
HP) for damage and replace if
needed.
Go to “MFP stapler assembly
sensor (deflector HP)
removal” on page 4-220.
3. Replace the output option if
problem remains.
Diagnostic information
2-69
Error
code or
message
28x.50
x = bin
number
Error contents
Left tamper home
position jam
Applies to:
Description/Action
The left tamper home position
is not detected by the sensor
(left tamper HP)
Possible repair actions
1. Check all the connections on
the output option controller
card.
2. Check the tamper drive belt
for damage and replace if
needed.
StapleSmart finisher
3. Replace the left tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
sensor (tamper HP left and
right) removal” on
page 4-217.
4. Replace the output option if
problem remains.
28x.51
x = bin
number
Right tamper home
position jam
Applies to:
The right tamper home position
is not detected by the sensor
(right tamper HP)
1. Check all the connections on
the output option controller
card.
2. Check the tamper drive belt
for damage and replace if
needed.
StapleSmart finisher
3. Replace the right tamper
motor assembly.
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the sensor (tamper
HP).
Go to “MFP stapler assembly
tamper drive motor
assembly removal” on
page 4-210.
4. Replace the output option if
problem remains.
28x.52
x = bin
number
Paddle control motor
timer error
A software failure has occurred
with the output option.
1. Turn the machine off/on.
The eject motor encoder is not
detected upon startup
1. Check all the connections on
the output option controller
card.
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.53
x = bin
number
Eject motor encoder
not detected
Applies to:
StapleSmart finisher
2-70 Service Manual
2. Replace the output option if
problem remains.
Error
code or
message
28x.54
x = bin
number
Error contents
Eject motor encoder
not detected
Applies to:
Description/Action
Possible repair actions
The eject motor encoder
detection is lost during normal
operation.
1. Check all the connections on
the output option controller
card.
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.55
x = bin
number
Eject motor
overspeed failure
The eject motor rotate at the
specified speed
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.56
x = bin
number
Eject motor
underspeed failure
The eject motor rotate at the
specified speed
Applies to:
x = bin
number
Sensor (stapler pass
through) static jam
Applies to:
Media remains on the sensor
(stapler pass through) during
the warm up sequence.
28x.58
28x.59
x = bin
number
Sensor (stapler pass
through) late jam
StapleSmart finisher
Staple ready home
position jam
Applies to:
StapleSmart finisher
Go to sensor (stapler pass
through) static jam service
check.
See “Sensor (stapler pass
through) static jam service
check” on page 2-145.
StapleSmart finisher
x = bin
number
1. Check all the connections on
the output option controller
card.
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.57
1. Check all the connections on
the output option controller
card.
The media is late reaching the
sensor (stapler pass through)
within the specified time.
See “Sensor (output pass
through) late jam service
check” on page 2-145.
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
assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.60
x = bin
number
The status of stapler
motor is not defined
Applies to:
A software failure has occurred
with the output option.
1. Turn the machine off/on.
2. Replace the output option if
problem remains.
StapleSmart finisher
Diagnostic information
2-71
Error
code or
message
28x.61
x = bin
number
Error contents
Description/Action
Possible repair actions
DMID command is not
received for 500ms
after main motor runs
A software failure has occurred
with the output option.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
The bin clamp home position is
not detected by the sensor (bin
clamp HP)
1. Turn the machine off/on.
The sensor (bin clamp HP)
does not detect that the bin
clamp has moved from home
position.
1. Turn the machine off/on.
A software failure has occurred
with the output option.
1. Turn the machine off/on.
2. Replace the output option if
problem remains.
Applies to:
StapleSmart finisher
28x.62
x = bin
number
When finishing job
isn't completed yet,
the first DMID
command of the next
job is received.
2. Replace the output option if
problem remains.
Applies to:
StapleSmart finisher
28x.63
x = bin
number
Bin clamp motor
control timer error.
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.64
x = bin
number
Bin clamp motor
control timer error
during tray holder
initial.
2. Replace the output option if
problem remains.
Applies to:
StapleSmart finisher
28x.65
x = bin
number
Bin clamp home
position jam
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.66
x = bin
number
Bin clamp home
position jam
Applies to:
2. Replace the output option if
problem remains.
StapleSmart finisher
28x.67
x = bin
number
Invalid bin clamp
manager state.
Applies to:
StapleSmart finisher
2-72 Service Manual
2. Replace the output option if
problem remains.
Error
code or
message
28x.68
x = bin
number
Error contents
Description/Action
Possible repair actions
Applies to:
The sensor (self priming) within
the stapler assembly does not
detect a ready staple prior to a
staple job.
1. Check all the connections on
the controller card and the
stapler assembly.
StapleSmart finisher
Staples empty
Staple ready home
position jam
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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.69
x = bin
number
Staple ready home
position jam
Applies to:
StapleSmart finisher
The 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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
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 assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
Diagnostic information
2-73
Error
code or
message
28x.70
x = bin
number
Error contents
Stapler mechanism
not in home position
failure
Applies to:
Description/Action
Possible repair actions
The sensor (home signal)
within the stapler assembly
detected that the stapler
mechanism was not in the
home position before stapling.
1. Check all the connections on
the controller card and the
stapler assembly.
StapleSmart finisher
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.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
4. Manually rotate the drive
gears and reset the stapler and
remove all jammed staples
then reinstall the stapler
assembly.
5. If problem remains, replace
the stapler assembly.
Go to “MFP stapler assembly
stapler unit assembly
removal” on page 4-212.
28x.71
x = bin
number
Deflector gate
transition to standard
bin not detected
Applies to:
The sensor (deflector gate HP)
does not detect transition of the
deflector gate to the standard
bin.
StapleSmart finisher
1. Check all the connections on
the output option controller
card.
2. Check the sensor (deflector
HP) for damage and replace if
needed.
Go to “MFP stapler assembly
sensor (deflector HP)
removal” on page 4-220.
3. Replace the output option if
problem remains.
281.72
x = bin
number
Sensor (media in
stapler) static jam
Applies to:
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)
StapleSmart finisher
Go to “MFP stapler assembly
sensor (media in stapler)
removal” on page 4-219.
290.00
Sensor (ADF sheet
through) static jam
Media remains on the sensor
(ADF sheet through) during the
warm up sequence.
See “Sensor (ADF sheet
through) static jam service
check” on page 2-112.
290.01
Sensor (ADF sheet
through) late jam
The media does not reach the
sensor (ADF sheet through)
within the specified time.
See “Sensor (ADF sheet
through) late jam service
check 290.01” on page 2-113.
290.02
Sensor (ADF 1st
scan) late jam
The media does not reach the
sensor (ADF 1st scan) within
the specified time.
See “Sensor (ADF 1st scan)
late jam service check” on
page 2-114.
2-74 Service Manual
Error
code or
message
Error contents
Description/Action
Possible repair actions
290.03
Sensor (ADF sheet
through) lingering jam
Media reached the sensor
(ADF sheet through) but did
not clear it within the specified
time.
See “Sensor (ADF sheet
through) lingering jam
service check” on
page 2-115.
290.10
Sensor (ADF 1st
scan) static jam
Media remains on the sensor
(ADF 1st scan) during the
warm up sequence.
See “Sensor (1st scan) static
jam service check” on
page 2-117.
291.00
Sensor (ADF 2nd
scan) static jam
Media remains on the sensor
(ADF 2nd scan) during the
warm up sequence.
See “Sensor (2nd scan)
static jam service check” on
page 2-118.
291.01
Sensor (ADF 2nd
scan) late jam
The media does not reach the
sensor (ADF 2nd scan) within
the specified time.
See Go to “Sensor (ADF 2nd
scan) late jam service check”
on page 2-149.
291.02
Sensor (ADF media
exit) late jam
The media does not reach the
sensor (ADF media exit) within
the specified time.
See “Sensor (ADF media
exit) late jam service check”
on page 2-123.
292.00
ADF top door open
jam
The ADF top door assembly
was opened while the ADF was
operating.
See “ADF top door open jam
service check” on
page 2-121.
293.00
Media missing jam
The media is removed from the
ADF once the feed process is
initiated.
See “Media missing jam
service check” on
page 2-121.
294.00
Sensor (ADF media
exit) static jam
Media remains on the sensor
(ADF media exit) during the
warm up sequence.
See “Sensor (ADF media
exit) static jam service
check” on page 2-122.
294.01
Sensor (ADF media
exit) lingering jam
Media reached the sensor
(ADF media exit) within the
specified time but did not clear
it within the specified time.
See “Sensor (ADF media
exit) lingering jam service
check” on page 2-125.
294.03
Sensor (ADF media
exit) lingering jam
Media reached the sensor
(ADF media exit) within the
specified time but did not clear
it within the specified time.
See “Sensor (ADF media
exit) lingering jam service
check” on page 2-125.
840.01
Scanner manually
disabled
The scanner has been
manually disabled
Enter the configuration mode to
re-enable the scanner.
840.02
Scanner auto
disabled
The scanner has automatically
been disabled by the controller
Enter the configuration mode to
re-enable the scanner.
841.xx
Scanner image
pipeline failure
The scanner image ASIC has
failed
1. Check all connections on the
ADF controller card assembly.
2. Replace the scanner
controller card assembly if
problem remains. Go to
“Scanner controller card
assembly removal (models
X651, X652/5535dn, X654,
and X656)” on page 4-132 or
“Scanner controller card
assembly removal (model
X658)” on page 4-129.
Diagnostic information
2-75
Error
code or
message
842.xx
Error contents
ADF communication
failure
Description/Action
The ADF controller card has
lost communication with the
system.
Possible repair actions
1. Check all connections on the
ADF controller card assembly.
2. Replace the ADF controller
card assembly if problem
remains.
Go to “ADF controller card
removal” on page 4-67.
843.xx
844.xx
Scanner carriage
mechanical failure
The scanner carriage home
position detection has failed.
Scanner exposure
lamp failure
The flatbed scanner exposure
lamp has failed.
1. Turn the machine off/on.
2. See “Sensor (scanner HP)
service check” on
page 2-149.
Replace the exposure lamp.
Go to “Scanner / ADF duplex
CCD exposure lamp
removal” on page 4-147.
845.xx
Scanner CCD failure
849.00
Missing a hard drive
Machine is missing a hard
drive.
Install the hard drive.
849.01
Hard drive installed
erroneously
Machine has an installed hard
drive that should not be
present.
Uninstall the hard drive.
900.xx
System software error
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
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
firmware related, or if the
customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
2-76 Service Manual
Error
code or
message
Error contents
Description/Action
Possible repair actions
902.xx
System software error
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
903.xx
Paperport link driver
error
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
904.xx
Interface violation by
RIP
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
905.xx
Interface violation by
paperport device
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Diagnostic information
2-77
Error
code or
message
Error contents
Description/Action
Possible repair actions
906.xx
RIP interface driver
error
Code detected unusual event
or timing.
1. POR the machine and print
a simple test page to
determine if the problem is
system software related, or
if the customer is sending a
corrupted print job.
2. Check all connections on
the system card assembly.
3. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
910.00
Pick arm motor stalled
failure
The pick arm motor has stalled
or become obstructed.
1. Check all the connections on
the pick arm assembly.
2. Check all the connections on
the system card assembly.
3. Replace the pick arm
assembly if problem remains.
Go to “Pick arm assembly
removal” on page 4-29.
911.00
Pick arm motor
overrun failure
The pick arm motor encoder
continues to detect pulse after
the motor stops.
1. Check all the connections on
the pick arm assembly.
2. Check all the connections on
the system card assembly.
3. Replace the pick arm
assembly if problem remains.
Go to “Pick arm assembly
removal” on page 4-29.
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.
Go to “Pick arm assembly
removal” on page 4-29.
913.00
Pick arm motor
overspeed 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.
Go to “Pick arm assembly
removal” on page 4-29.
2-78 Service Manual
Error
code or
message
914.00
Error contents
Description/Action
Possible repair actions
Pick arm motor no
encoder not detected
failure
The pick arm motor encoder
detection is lost during normal
operation
1. Check all the connections on
the pick arm assembly.
2. Check all the connections on
the system card assembly.
3. Replace the pick arm
assembly if problem remains.
Go to “Pick arm assembly
removal” on page 4-29.
914.01
Pick arm motor
overspeed 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.
Go to “Pick arm assembly
removal” on page 4-29.
915.00
Redrive motor
encoder not detected
failure
The redrive motor encoder
detection is lost during normal
operation
1. Check all the connections on
the duplex drive motor
assembly.
2. Check all the connections on
the system card assembly.
3. Replace the duplex drive
motor assembly if problem
remains.
Go to “Duplex drive motor
assembly removal” on
page 4-9.
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.
Go to “Duplex drive motor
assembly removal” on
page 4-9.
916.00
Internal duplex drive
motor encoder not
detected failure
The duplex drive motor
encoder detection is lost during
normal operation
1. Check all the connections on
the duplex drive motor
assembly.
2. Check all the connections on
the system card assembly.
3. Replace the duplex drive
motor assembly if problem
remains.
Go to “Duplex drive motor
assembly removal” on
page 4-9.
Diagnostic information
2-79
Error
code or
message
916.01
Error contents
Internal duplex drive
motor over speed
failure
Description/Action
The duplex drive motor does
not rotate at the specified
speed.
Possible repair actions
1. Check all the connections on
the duplex drive motor
assembly.
2. Check all the connections on
the system card assembly.
3. Replace the duplex drive
motor assembly if problem
remains.
Go to “Duplex drive motor
assembly removal” on
page 4-9.
920.00
Fuser under
temperature
Fuser type = 1
920.01
Fuser warm-up failure
Fuser type = 1
920.02
Fuser warm-up failure
Fuser type = 1
920.03
Fuser warm-up failure
Fuser type = 1
2-80 Service Manual
Fuser does not maintain proper
operating temperature within
steady state 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
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The fuser hot roll took too long
to heat up after transitioning to
new enhanced mode within
standby control only.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
Error
code or
message
920.04
Error contents
Description/Action
Possible repair actions
Fuser warm-up failure
The fuser hot roll is too cool
when heating to desired
temperature after slope change
within standby control only.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The fuser hot roll temperature
does not increase while the
lamp is turned on.
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. Ensure the proper voltage
setting is being used on the
switchable LVPS assembly.
5. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
6. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
The fuser hot roll temperature
is not maintained properly
while the media in the fuser
nip.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser type = 1
920.06
Fuser warm-up failure
Fuser type = 1
920.07
Fuser warm-up failure
Fuser type = 1
Diagnostic information
2-81
Error
code or
message
920.25
Error contents
Fuser under
temperature
Fuser type = 2
920.26
Fuser warm-up failure
Fuser type = 2
920.27
Fuser warm-up failure
Fuser type = 2
920.28
Fuser warm-up failure
Fuser type = 2
920.29
Fuser warm-up failure
Fuser type = 2
2-82 Service Manual
Description/Action
Possible repair actions
Fuser does not maintain proper
operating temperature within
steady state 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
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The fuser hot roll took too long
to heat up after transitioning to
new enhanced mode within
standby control only.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The fuser hot roll is too cool
when heating to desired
temperature after slope change
within standby control only.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
Error
code or
message
920.31
Error contents
Fuser warm-up failure
920.50
Possible repair actions
The fuser hot roll temperature
does not increase while the
lamp is turned on.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser type = 2
The fuser hot roll temperature
is not maintained properly
while the media in the fuser
nip.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser under
temperature
Fuser does not maintain proper
operating temperature within
steady state control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll took too long
to heat up after transitioning to
new enhanced mode within
standby control only.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll fell to far
below desired temperature
while in standby control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser type = 2
920.32
Description/Action
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
920.51
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
920.52
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
Diagnostic information
2-83
Error
code or
message
920.53
Error contents
Fuser warm-up failure
Fuser type = 1
Description/Action
The fuser hot roll is too cool
while checking for slope
change in standby.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll is too cool
when heating to desired
temperature after slope change
within standby control only.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll temperature
does not increase while the
lamp is turned on.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll temperature
is not maintained properly
while the media in the fuser
nip.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser does not maintain proper
operating temperature within
steady state control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll took too long
to heat up after transitioning to
new enhanced mode within
standby control only.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll fell to far
below desired temperature
while in standby control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll is too cool
while checking for slope
change in standby.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll is too cool
when heating to desired
temperature after slope change
within standby control only.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll temperature
does not increase while the
lamp is turned on.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser page count has
exceeded life.
920.54
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
920.56
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
920.57
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
920.75
Fuser under
temperature
Fuser type = 2
Possible repair actions
Fuser page count has
exceeded life.
920.76
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
920.77
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
920.78
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
920.79
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
920.81
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
2-84 Service Manual
Error
code or
message
920.82
Error contents
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.00
Fuser warm-up failure
Fuser type = 1
922.02
Fuser warm-up failure
Fuser type = 1
922.03
Fuser warm-up failure
Fuser type = 1
Description/Action
The fuser hot roll temperature
is not maintained properly
while the media in the fuser
nip.
Possible repair actions
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll failed to
reach target departure.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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 LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
The fuser hot roll does reach
the “final lamp detection”
parameter but not in the
specified time.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Diagnostic information
2-85
Error
code or
message
922.04
922.05
Error contents
Description/Action
Possible repair actions
Fuser warm-up failure
Fuser type = 1
The fuser hot roll has timed out
and not reached “final lamp
detection” during the specified
time.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
After hot roll lamp
detection, did not roll
over to steady state
control in time.
The control code has gotten
lost (this should really be a
software error.
Turn the machine off/on.
Fuser type = 1
922.06
Fuser warm-up failure
Fuser type = 1
2-86 Service Manual
The fuser hot roll did not reach
operating temperature within
new enhanced control.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Error
code or
message
922.07
Error contents
Description/Action
Possible repair actions
Fuser warm-up failure
The fuser hot roll does not
reach operating temperature
after increasing interpage gap.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
The fuser hot roll failed to
reach target departure.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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 LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser type = 1
922.25
Fuser warm-up failure
Fuser type = 2
922.27
Fuser warm-up failure
Fuser type = 2
Diagnostic information
2-87
Error
code or
message
922.28
Error contents
Fuser warm-up failure
922.30
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser type = 2
The fuser hot roll has timed out
and not reached “final lamp
detection” during the specified
time.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
After hot roll lamp
detection, did not roll
over to steady state
control in time.
The control code has gotten
lost (this should really be a
software error.
Fuser warm-up failure
Fuser type = 2
2-88 Service Manual
Possible repair actions
The fuser hot roll does reach
the “final lamp detection”
parameter but not in the
specified time.
Fuser type = 2
922.29
Description/Action
Turn the machine off/on.
Error
code or
message
922.31
Error contents
Description/Action
Possible repair actions
Fuser warm-up failure
The fuser hot roll did not reach
operating temperature within
new enhanced control.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
The fuser hot roll does not
reach operating temperature
after increasing interpage gap.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Check all connections on
the fuser and LVPS card
assembly.
4. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
5. Replace the LVPS card
assembly if problem
remains. Go to “LVPS card
assembly removal” on
page 4-47.
Fuser type = 2
922.32
Fuser warm-up failure
Fuser type = 2
922.50
Fuser warm-up failure
Fuser type = 1
The fuser hot roll failed to
reach target temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does not
reach the “beginning lamp
detection” parameter in the
specified time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does reach
the “final lamp detection”
parameter but not in the
specified time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser page count has
exceeded life.
922.52
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
922.53
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
Diagnostic information
2-89
Error
code or
message
922.54
Error contents
Description/Action
Fuser warm-up failure
The fuser hot roll has timed out
and not reached “final lamp
detection” during the specified
time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll did not reach
operating temperature within
new enhanced control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does not
reach operating temperature
after increasing interpage gap.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll failed to
reach target temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does not
reach the “beginning lamp
detection” parameter in the
specified time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does reach
the “final lamp detection”
parameter but not in the
specified time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll has timed out
and not reached “final lamp
detection” during the specified
time.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll did not reach
operating temperature within
new enhanced control.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll does not
reach operating temperature
after increasing interpage gap.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser type = 1
Fuser page count has
exceeded life.
922.56
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
922.57
Fuser warm-up failure
Fuser type = 1
Fuser page count has
exceeded life.
922.75
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.77
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.78
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.79
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.81
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
922.82
Fuser warm-up failure
Fuser type = 2
Fuser page count has
exceeded life.
2-90 Service Manual
Possible repair actions
Error
code or
message
923.00
Error contents
Fuser over
temperature failure.
Fuser type = 1
923.01
Fuser over
temperature failure.
Fuser type = 1
923.25
Fuser over
temperature failure.
Fuser type = 2
923.26
Fuser over
temperature failure.
Fuser type = 2
923.50
Fuser over
temperature failure.
Fuser type = 1
923.51
Fuser over
temperature failure.
Fuser type = 1
Description/Action
Possible repair actions
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
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
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The fuser hot roll has
exceeded the proper operating
temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll has
exceeded the proper operating
temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Diagnostic information
2-91
Error
code or
message
923.75
Error contents
Fuser over
temperature failure.
Fuser type = 2
923.76
Fuser over
temperature failure.
Fuser type = 2
924.00
Open fuser thermistor
check
Description/Action
The fuser hot roll has
exceeded the proper operating
temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser hot roll has
exceeded the proper operating
temperature.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor might be
faulty.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor has failed.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor might be
faulty.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor has failed.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor might be
faulty.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor has failed.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor might be
faulty.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
The fuser thermistor has failed.
Replace the fuser unit
assembly if problem remains.
Go to “Fuser unit assembly
removal” on page 4-15.
Fuser type = 1
924.01
Open fuser thermistor
check failure.
Fuser type = 1
924.25
Open fuser thermistor
check
Fuser type = 2
924.26
Open fuser thermistor
check failure.
Fuser type = 2
924.50
Open fuser thermistor
check
Possible repair actions
Fuser type = 1
Fuser page count has
exceeded life.
924.51
Open fuser thermistor
check failure.
Fuser type = 1
Fuser page count has
exceeded life.
924.75
Open fuser thermistor
check
Fuser type = 2
Fuser page count has
exceeded life.
924.76
Open fuser thermistor
check failure.
Fuser type = 2
Fuser page count has
exceeded life.
2-92 Service Manual
Error
code or
message
925.00
Error contents
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
925.01
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
925.02
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
925.25
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
925.26
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
Description/Action
Possible repair actions
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
Diagnostic information
2-93
Error
code or
message
925.27
Error contents
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
925.50
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
Description/Action
Possible repair actions
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
Fuser page count has
exceeded life.
925.51
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
Fuser page count has
exceeded life.
925.52
Incorrect fuser or
fuser lamp detected.
Fuser type = 1
Fuser page count has
exceeded life.
925.75
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
Fuser page count has
exceeded life.
2-94 Service Manual
Error
code or
message
925.76
Error contents
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
Description/Action
Possible repair actions
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
The machine detected a 115 V
lamp in a 220 V machine. The
fuser lamp has an excessive
wattage rating.
1. Turn the machine off/on
and ensure the fuser unit
assembly is properly
installed.
2. Ensure the proper voltage
fuser is installed in the
machine.
3. Replace the fuser unit
assembly if problem
remains. Go to “Fuser unit
assembly removal” on
page 4-15.
Fuser page count has
exceeded life.
925.77
Incorrect fuser or
fuser lamp detected.
Fuser type = 2
Fuser page count has
exceeded life.
927.01
Main cooling fan
failure.
The cooling fan is obstructed or
has failed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
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
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
927.03
Main cooling fan
control failure.
The main cooling fan does not
reach the specified speed.
4. Check for cooling fan
obstructions.
5. Check the connections on
the main cooling fan.
6. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
927.04
Main cooling fan
under speed failure
The main cooling fan does not
reach the specified speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
Diagnostic information
2-95
Error
code or
message
Error contents
Description/Action
Possible repair actions
927.05
Main cooling fan over
speed failure.
The main cooling fan does not
reach the specified speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
927.06
Main cooling fan over
speed failure.
The main cooling fan does not
reach the specified speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
927.07
Main cooling fan over
speed failure.
The main cooling fan does not
reach the specified speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the main cooling
fan. Go to “Main cooling
fan removal” on
page 4-14.
927.11
Print cartridge cooling
fan failure
The print cartridge 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
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
927.13
Print cartridge cooling
fan control failure.
The Print cartridge cooling fan
does not reach the specified
speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the print cartridge
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
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 cartridge
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
927.15
Print cartridge cooling
fan over speed failure.
The Print cartridge cooling fan
does not reach the specified
speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the print cartridge
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
2-96 Service Manual
Error
code or
message
Error contents
Description/Action
Possible repair actions
927.16
Print cartridge cooling
fan over speed failure.
The Print cartridge cooling fan
does not reach the specified
speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the print cartridge
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
927.17
Print cartridge cooling
fan over speed failure.
The Print cartridge cooling fan
does not reach the specified
speed.
1. Check for cooling fan
obstructions.
2. Check the connections on
the main cooling fan.
3. Replace the print cartridge
cooling fan. Go to “Print
cartridge cooling fan
removal” on page 4-31.
927.21
LVPS cooling fan
failure.
LVPS 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 LVPS cooling
fan. Go to “LVPS cooling
fan” on page 4-154.
929.01
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 cartridge
for damage and replace the
print cartridge if needed.
2. Check the sensor (toner
empty) for proper
operation. See “Sensor
(ADF sheet through)
static jam service check”
on page 2-112.
929.02
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 cartridge
for damage and replace the
print cartridge if needed.
2. Check the sensor (toner
empty) for proper
operation. See “Sensor
(ADF sheet through)
static jam service check”
on page 2-112.
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 cartridge
for damage and replace the
print cartridge if needed.
2. Check the sensor (toner
empty) for proper
operation. See “Sensor
(ADF sheet through)
static jam service check”
on page 2-112.
930.00
Incorrect printhead or
intermittent Hsync
A non supported printhead is
installed. Hsync signal is
intermittent or noisy. Printhead
ID resistor circuit is not to spec.
Replace the printhead
assembly. Go to “Printhead
assembly removal” on
page 4-34.
Diagnostic information
2-97
Error
code or
message
Error contents
Description/Action
Possible repair actions
931.00
No first laser H sync
The hsync signal is missing or
not at the correct voltage.
Replace the printhead
assembly. Go to “Printhead
assembly removal” on
page 4-34.
932.00
Printhead lost laser H
syncs.
The hsync signal is missing or
not at the correct voltage.
Replace the printhead
assembly. Go to “Printhead
assembly removal” on
page 4-34.
933.00
Polygon mirror motor
locked. No first laser
H sync received.
The hsync signal is missing or
not at the correct voltage.
Replace the printhead
assembly. Go to “Printhead
assembly removal” on
page 4-34.
934.00
Mirror motor lost lock.
The signals driving the polygon
motor may have been
corrupted, or the cable may be
loose, or the motor may be
bad.
1. Check all connections on
the printhead assembly.
2. Check all connections on
the system card assembly.
3. Replace the printhead
assembly. Go to
“Printhead assembly
removal” on page 4-34.
935.00
Polygon mirror motor
control failure.
The signals driving the polygon
mirror motor may have been
corrupted, or the cable may be
loose, or the motor may be
bad.
1. Check all connections on
the printhead assembly.
2. Check all connections on
the system card assembly.
3. Replace the printhead
assembly. Go to
“Printhead assembly
removal” on page 4-34.
936.10
Main drive motor
assembly failure
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
No halls detected at
motor start.
Motor = type 0
936.11
Main drive motor
assembly failure
No halls detected at
motor start.
Motor = type 1
2-98 Service Manual
Error
code or
message
936.20
Error contents
Main drive motor
assembly failure
Description/Action
Possible repair actions
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Failed to stop within
timeout.
Motor = type 0
936.21
Main drive motor
assembly failure
Failed to stop within
timeout.
Motor = type 1
936.30
Main drive motor
assembly failure
No lock detected at
motor start for motor
ID.
Motor = type 0
936.31
Main drive motor
assembly failure
No lock detected at
motor start for motor
ID.
Motor = type 1
Diagnostic information
2-99
Error
code or
message
936.60
Error contents
Main drive motor
assembly failure
Description/Action
Possible repair actions
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
No lock detected at
normal motor start.
Motor = type 0
936.61
Main drive motor
assembly failure
No lock detected at
normal motor start.
Motor = type 1
936.90
Main drive motor
assembly failure
Stall detected during
speed control.
Motor = type 0
936.91
Main drive motor
assembly failure
Stall detected during
speed control.
Motor = type 1
2-100 Service Manual
Error
code or
message
937.40
Error contents
Main drive motor
assembly failure
Description/Action
Possible repair actions
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Over speed detected
during speed control.
Motor = type 0
937.41
Main drive motor
assembly failure
Over speed detected
during speed control.
Motor = type 1
937.50
Main drive motor
assembly failure
Over speed detected
during position
control.
Motor = type 0
937.51
Main drive motor
assembly failure
Over speed detected
during position
control.
Motor = type 1
Diagnostic information
2-101
Error
code or
message
937.70
Error contents
Description/Action
Possible repair actions
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
Main drive motor
assembly failure
The main drive motor assembly
may be faulty or has failed.
Loss of lock detected
by higher-level code.
The internal duplex assembly
is not properly grounded to the
LVPS. This only applies to
machines with an installed
internal duplex assembly.
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.
Main drive motor
assembly failure
Loss of lock detected
by higher-level code.
Motor = type 0
937.71
Motor = type 1
LVPS
Grounding wire
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 assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
2-102 Service Manual
Error
code or
message
937.80
Error contents
Main drive motor
assembly failure
Description/Action
Possible repair actions
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The main drive motor assembly
may be faulty or has failed.
1. Check all connections on
the system card assembly.
2. Check all connections on
the main drive motor
assembly.
3. Replace the main drive
motor assembly. Go to
“Main drive motor
assembly removal” on
page 4-20.
4. Replace the system card
assembly if problem
remains. Go to “System
card assembly removal”
on page 4-50.
The image processing ASIC or
DRAM has failed.
1. POR the machine
2. If the problem remains,
replace the scanner
controller card. Go to
“Scanner controller card
assembly removal (model
X658)” on page 4-129 or
“Scanner controller card
assembly removal
(models X651,
X652/5535dn, X654, and
X656)" on page 4-132.
Driver over temp
detection.
Motor = type 0
937.81
Main drive motor
assembly failure
Driver over temp
detection.
Motor = type 1
945.xxx
Image processing unit
failure
Diagnostic information
2-103
Error
code or
message
950.xx
Error contents
NVRAM mismatch
failure
Description/Action
Mismatch between system
card EEPROM and operator
panel mirror.
".xx" codes:
00-29: mismatch between
system and mirror
30-60: mismatch between
secure and system
Possible repair actions
Warning: When replacing any
of the following components:
• Scanner interface card
assembly.
• System card assembly
Only replace one component at
a time. Replace the required
component and perform a POR
before replacing a second
component listed above. If this
procedure is not followed, the
printer will be rendered
inoperable. Never replace two
or more of the components
listed above without a POR
after installing each one or the
printer will be rendered
inoperable.
Never install and remove
components listed above as a
method of troubleshooting
components. Once a
component has been installed
in a machine, it can not be
used in another machine. It
must be returned to the
manufacturer.
Go to NVRAM mismatch failure
service check.
See “NVRAM mismatch
failure (950.00 through
950.29) service check” on
page 2-150.
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.
NVRAM chip failure with
system card assembly.
Replace the system card
assembly.
954.xx
NVRAM failure
Go to “Scanner interface
card assembly removal” on
page 4-148.
Go to “System card
assembly removal” on
page 4-50.
955.xx
956.xx
NAND FLASH Failure
System card
processor failure
The Code ROM or NAND flash
failed the Cyclic Redundancy
Check (CRC) check or the
NAND experienced an
uncorrectible multi-bit failure.
Replace the system card
assembly.
The processor has failed on
the system card assembly.
Replace the system card
assembly.
Go to “System card
assembly removal” on
page 4-50.
Go to “System card
assembly removal” on
page 4-50.
2-104 Service Manual
Error
code or
message
956.01
957.xx
Error contents
Description/Action
Possible repair actions
System card
processor over
temperature
The system card processor is
over temperature or is
damaged.
Replace the system card
assembly.
System card ASIC
failure
The ASIC has failed on the
system card assembly.
Replace the system card
assembly.
Go to “System card
assembly removal” on
page 4-50.
Go to “System card
assembly removal” on
page 4-50.
958.xx
959.xx
NAND failure
Print cartridge
authentication failure
Printer has performed more
than 100 "shift and reflash"
operations as a result of ECC
bit corrections
Replace the system card
assembly.
The system card can not
properly authenticate the print
cartridge or the authentication
process has failed.
Replace the system card
assembly.
Go to “System card
assembly removal” on
page 4-50.
Go to “System card
assembly removal” on
page 4-50.
960.xx
Memory failure
RAM Memory Error: RAM
soldered on the card is bad
Replace the appropriate
memory module.
961.xx
Memory failure
RAM Memory Error: Slot 1
RAM is bad
Replace the appropriate
memory module.
962.xx
Memory failure
RAM 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. Disable the Download
Emulation. Program the
download emulation into the
firmware card again.
1.
2. Replace the system card
assembly if problem remains.
Go to “System card
assembly removal” on
page 4-50.
975.xx
Network Error
The system detected an
unrecognizable network port
976.xx
Network Error
The system detected an
unrecoverable software error in
network port
978.xx
Network Error
The system detected a bad
checksum while programming
network port
979.xx
Network Error
The flash parts failed while
programming a network port
Diagnostic information
2-105
Error
code or
message
982.04
Error contents
Output option
communication
failure.
Description/Action
An output option was not fully
seated onto the printer or has
been removed while the main
power is turned on.
Possible repair actions
1. Turn the main power off.
2. Remove and reinstall the
output option.
3. Turn the main power back
on.
4. Check all output option
interface connections if
problem remains.
982.07
Too many options
installed
Exceeded the maximum
number of input or output
options.
Remove the appropriate input
or output options.
990.00
Output option
equipment check.
Output option rear door not
fully closed.
Close the rear door on all
output options.
990.51
HCIT tray lift motor
PWM underflow error
The HCIT tray lift motor does
not operate at the specified
speed reported by tray x
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
motor drive motor assembly if
problem remains. Go to “High
capacity input tray (HCIT)
tray lift drive motor assembly
removal” on page 4-167.
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
problem remains. Go to “High
capacity input tray (HCIT)
tray lift drive motor assembly
removal” on page 4-167.
990.54
HCIT tray lift motor
lost encoder failure
The HCIT tray lift motor is not
reporting pulses back to the
engine.
1. Check for obstruction in the
HCIT tray lift area.
2. Check the connections on
the HCIT tray lift motor
assembly for proper
connection.
3. Replace the HCIT tray lift
drive motor assembly if
problem remains. Go to “High
capacity input tray (HCIT)
tray lift drive motor assembly
removal” on page 4-167.
2-106 Service Manual
Service checks
Sensor (input) service check
Step
1
Check
Check the sensor (input) for damage.
Yes
Go to step 2.
Is the above component free from damage?
No
Replace the
sensor (input).
Go to “Sensor
(input) removal”
on page 4-42.
2
1. Enter the diagnostic mode
2. Select Base sensor test
The sensor is
working properly
Go to step 2.
Replace the
Sensor (input).
Replace the
connection.
4. 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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(input) removal”
on page 4-42.
Sensor (fuser output) service check
Step
1
Check
Check the sensor (fuser output) for damage.
Yes
Go to step 2.
Is the above component free from damage?
No
Replace fuser unit
assembly.
Go to “Fuser unit
assembly
removal” on
page 4-15.
2
1. Enter the diagnostic mode
2. Select Base sensor test
The sensor is
working properly
Go to step 2.
Replace the fuser
unit assembly.
Replace the
connection.
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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
Diagnostic information
2-107
Sensor (narrow media) service check
Step
1
Check
Check the sensor (narrow media) for damage.
Yes
Go to step 2.
Is the above component free from damage?
No
Replace the fuser
unit assembly.
Go to “Fuser unit
assembly
removal” on
page 4-15.
2
1. Enter the diagnostic mode
2. Select Base sensor test
The sensor is
working properly
Go to step 2.
Replace fuser unit
assembly.
Replace the
connection.
4. Observe the line item “narrow media”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
Sensor (duplex input) service check
Step
1
Check
Check the sensor (duplex input) for damage.
Yes
Go to step 2.
Is the above component free from damage?
No
Replace the
sensor (duplex
input).
Go to “Sensor
(duplex input)
removal” on
page 4-41.
2
1. Enter the diagnostic mode
2. Select Duplex sensor tests
The sensor is
working properly
Go to step 2.
Replace the
duplex input
sensor assembly
(internal duplex
only).
Replace the
connection.
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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Duplex
input sensor
assembly
removal” on
page 4-10.
or replace the
external duplex
unit assembly
(external duplex
only).
2-108 Service Manual
Sensor (duplex input) service check (external duplex only)
Step
1
Check
Check the sensor (duplex input) for damage.
Yes
Go to step 2.
Replace the
external duplex
unit assembly.
The sensor is
working properly
Go to step 2.
Replace the
external duplex
unit assembly.
Replace the
connection.
Is the above component free from damage?
2
1. Enter the diagnostic mode
2. Select Duplex sensor tests
No
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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Sensor (duplex exit) service check (external duplex only)
Step
1
Check
Check the sensor (duplex exit) for damage.
Yes
Go to step 2.
Replace the
external duplex
unit assembly.
The sensor is
working properly
Go to step 2.
Replace the
external duplex
unit assembly.
Replace the
connection.
Is the above component free from damage?
2
1. Enter the diagnostic mode
2. Select Duplex sensor tests
No
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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Sensor (pass through) service check
Step
1
Check
1. Enter the diagnostic mode
2. Select Input tray tests
Yes
The sensor is
working properly
No
Go to step 2.
3. Select Sensor test
4. Select the appropriate tray number
5. Observe the line item “pass through” for the appropriate
media tray
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
Diagnostic information
2-109
Step
2
Check
Check the above sensor for proper connection.
Is the above sensor connected properly?
Yes
Replace the
sensor (pass
through).
No
Replace the
connection.
Go to “Sensor
(pass through)
with cable
removal” on
page 4-198.
Sensor (envelope feeder empty) service check
Step
1
Check
1. Enter the diagnostic mode
2. Select Input tray tests
Yes
No
The sensor is
working properly
Go to step 2.
Replace the
envelope feeder.
Replace the
connection.
3. Select Sensor test
4. Select Envelope feeder
5. Observe the line item “empty”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
2
Check the above sensor for proper connection.
Is the above sensor connected properly?
Sensor (ADF top door interlock) service check
Step
1
Check
1. Enter the diagnostic mode
2. Select Scanner tests
Yes
No
The sensor is
working properly
Go to step 2.
Replace the
sensor (ADF top
door interlock).
Replace the
connection.
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 interrupted or
blocked.
2
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to Go to
“Sensor (ADF top
door interlock)
removal” on
page 4-80.
2-110 Service Manual
Switch (ADF closed interlock) jam service check
Step
1
Check
1. Enter the diagnostic mode
2. Select Scanner tests
Yes
No
The sensor is
working properly
Go to step 2.
Replace the
sensor (ADF
closed interlock).
Replace the
connection.
3. Select Sensor tests
4. Observe the line item “sensor (ADF closed interlock)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
2
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Switch
(ADF closed
interlock)
removal” on
page 4-84.
Diagnostic information
2-111
Sensor (ADF sheet through) static jam service check
Use this procedure for the following jams:
• 290.00
1
Check the media path.
Go to step 2.
Remove any
media or media
fragments.
Go to step 4.
Go to step 3.
Is the media path free of media or media fragments?
2
Check the sensor (ADF sheet through) for proper operation.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF sheet through”.
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the sensor (ADF sheet through) for proper connection. Replace the
sensor (ADF
Is the above component properly connected?
sheet through).
Replace the
connection.
Go to “Sensor
(ADF sheet
through)
removal” on
page 4-82.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
2-112 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF sheet through) late jam service check 290.01
Use this procedure for the following jams:
• 290.01
Step
1
Check
Check the original document condition.
Yes
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.
Go to step 3.
Clean or replace
the ADF feed/pick
roll assembly or
the ADF
separation roll
assembly.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
2
Check the ADF pick roll assembly for wear or gear damage.
No
Is the ADF feed/pick roll assembly or the ADF separation roll
assembly free of excess wear or gear damage?
Go to “ADF feed
/ pick roll
assembly
removal” on
page 4-61 or
“ADF separator
torque limiter
assembly
removal” on
page 4-63.
3
Check the media path for contaminates.
Go to step 4.
Remove all
contaminates
from the media
path.
Replace the ADF
feed drive motor
assembly.
Replace the
connection.
Is the media path free of excess media dust and foreign
objects such as paper clips and staples?
4
Check the ADF feed drive motor assembly for proper
connection.
Is the above component properly connected?
Go to “ADF feed
drive motor
assembly
removal” on
page 4-77.
5
Check the sensor (ADF sheet through) for proper operation.
Go to step 7.
Go to step 6.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF sheet through)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
Diagnostic information
2-113
Step
6
Check
Check the sensor (ADF sheet through) for proper
connection.
Is the above component properly connected?
Yes
Replace the
sensor (ADF
sheet through).
No
Replace the
connection.
Go to “Sensor
(ADF sheet
through)
removal” on
page 4-82.
7
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 11.
8
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF 1st scan) late jam service check
Use this procedure for the following jams:
• 290.02
Step
1
Check
Check the original document condition.
Yes
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.
Go to step 3.
Clean or replace
the ADF feed/pick
roll assembly or
the ADF
separation roll
assembly.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
2
Check the ADF rolls for wear.
No
Is the ADF feed/pick roll assembly or the ADF separation roll
guide assembly free of excess wear?
Go to “ADF feed /
pick roll
assembly
removal” on
page 4-61 or
“ADF separator
torque limiter
assembly
removal” on
page 4-63.
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?
2-114 Service Manual
Go to step 4.
Remove all
contaminates
from the media
path.
Step
4
Check
Check the sensor (ADF 1st scan) for proper operation.
Yes
No
Go to step 6.
Go to step 5.
Replace the
sensor (ADF 1st
scan).
Replace the
connection.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF 1st scan)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
5
Check the sensor (ADF 1st scan) for proper connection.
Is the above component properly connected?
Go to “Sensor
(ADF 1st scan)
removal” on
page 4-82.
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.
Go to “ADF feed
drive motor
assembly
removal” on
page 4-77.
7
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 8.
8
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF sheet through) lingering jam service check
Use this procedure for the following jams:
• 290.03
Step
1
Check
Check the media size setup and tray guides for the ADF.
Does the media size, in use, match the size set for the ADF
Yes
Go to step 2.
No
Replace the
media, or change
the media size
setup.
Diagnostic information
2-115
Step
2
Check
Check the original document condition.
Yes
Go to step 3.
Remove damaged
original document
and replace with a
new undamaged
original document.
Perform a ADF
test. If the problem
remains, go to
step 2.
Go to step 4.
Remove all
contaminates from
the media path.
Go to step 6.
Go to step 5.
Replace the
sensor (ADF
sheet through).
Replace the
connection.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
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?
4
Check the sensor (ADF sheet through) for proper operation.
No
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF sheet through)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
5
Check the sensor (ADF sheet through) for proper
connection.
Is the above component properly connected?
Go to “Sensor
(ADF sheet
through)
removal” on
page 4-82.
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.
Go to “ADF feed
drive motor
assembly
removal” on
page 4-77.
7
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.
Go to “ADF
transport drive
motor bracket
assembly w/
cable removal”
on page 4-77.
8
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 11.
9
Perform a print test using the ADF.
Does the problem remain?
2-116 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Sensor (1st scan) static jam service check
Use this procedure for the following jams:
• 290.10
1
Check the media path.
Go to step 2.
Remove any
media or media
fragments.
Go to step 4.
Go to step 3.
Replace the
sensor (ADF 1st
scan).
Replace the
connection.
Is the media path free of media or media fragments?
2
Check the sensor (ADF 1st scan) for proper operation.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF 1st can)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the sensor (ADF 1st scan) for proper connection.
Is the above component properly connected?
Go to “Sensor
(ADF 1st scan)
removal” on
page 4-82.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-117
Sensor (2nd scan) static jam service check
Use this procedure for the following jams:
• 291.00
1
Check the media path.
Go to step 2.
Remove any
media or media
fragments.
Go to step 4.
Go to step 3.
Replace the
sensor (ADF 2nd
scan).
Replace the
connection.
Is the media path free of media or media fragments?
2
Check the sensor (2nd scan) for proper operation.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Touch Observe the line “sensor (ADF 2nd scan)
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the sensor (ADF 2nd scan) for proper connection.
Is the above component properly connected?
Go to “Sensor
(ADF 2nd scan)
removal” on
page 4-81.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (2nd scan) lingering jam service check
Use this procedure for the following jams:
• 291.01
Step
1
Check
Check the media size setup and tray guides for the ADF.
Does the media size, in use, match the size set for the ADF
2-118 Service Manual
Yes
Go to step 2.
No
Replace the
media, or change
the media size
setup.
Step
2
Check
Check the original document condition.
Yes
Go to step 3.
Remove damaged
original document
and replace with a
new undamaged
original document.
Perform a ADF
test. If the problem
remains, go to
step 2.
Go to step 4.
Remove all
contaminates from
the media path.
Go to step 6.
Go to step 5.
Replace the
sensor (ADF 2nd
scan).
Replace the
connection.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
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?
4
Check the sensor (ADF 2nd scan) for proper operation.
No
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF 2nd scan)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
5
Check the sensor (ADF 2nd scan) for proper connection.
Is the above component properly connected?
Go to “Sensor
(ADF 2nd scan)
removal” on
page 4-81.
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.
Go to “ADF
transport drive
motor bracket
assembly w/
cable removal”
on page 4-77.
7
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 8.
8
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF media exit) late jam service check
Use this procedure for the following jams:
• 291.02
Diagnostic information
2-119
Step
1
Check
Check the original document condition.
Yes
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.
Go to step 3.
Remove all
contaminates from
the media path.
Go to step 5.
Go to step 4.
Replace the
sensor (ADF
media exit).
Replace the
connection.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
2
Check the media path for contaminates.
Is the media path free of excess media dust and foreign
objects such as paper clips and staples?
3
Check the sensor (ADF media exit) for proper operation.
No
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 time
the sensing area of the above sensor is interrupted or
blocked?
4
Check the sensor (ADF media exit) for proper connection.
Is the above component properly connected?
Go to Go to
“Sensor
(standard bin
exit) actuator
assembly
removal” on
page 4-89 or
“Sensor (ADF
media exit)
bracket
assembly
removal (X651)”
on page 4-90.
5
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.
Go to “ADF
transport drive
motor bracket
assembly w/
cable removal”
on page 4-77.
6
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 7.
7
Perform a print test using the ADF.
Does the problem remain?
2-120 Service Manual
Contact next
highest level of
tech support.
Problem solved.
ADF top door open jam service check
Use this procedure for the following jams:
• 292.00
Step
1
Check
Remove all documents from the ADF.
Yes
No
Go to step 2.
Problem solved
Go to step 4.
Go to step 3.
Replace the
sensor (ADF top
door interlock).
Replace the
connection.
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
2
Check the sensor (ADF top door interlock) for proper
operation.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Observe the line “sensor (ADF top door interlock)”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the sensor (ADF top door interlock) for proper
connection.
Is the above component properly connected?
Go to “Sensor
(ADF top door
interlock)
removal” on
page 4-80.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Media missing jam service check
Use this procedure for the following jams:
• 293.00
Step
1
Check
Remove all documents from the ADF.
Yes
Go to step 2.
No
Problem solved
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Diagnostic information
2-121
Step
2
Check
Yes
Check the sensor (ADF document set) for proper operation. Go to step 6.
No
Go to step 5.
1. Enter the Diagnostics Menu.
2. Touch SCANNER TESTS.
3. Touch Sensor Tests.
4. Touch TBD
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the sensor (2nd scan) for proper connection.
Is the above component properly connected?
Replace the
sensor (ADF
document set).
Replace the
connection.
Go to “Sensor
(ADF document
set) removal” on
page 4-83.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Go to step 2.
Remove any
media or media
fragments.
Go to step 4.
Go to step 3.
Sensor (ADF media exit) static jam service check
Use this procedure for the following jams:
• 294.00
1
Check the media path.
Is the media path free of media or media fragments?
2
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 time
the sensing area of the above sensor is interrupted or
blocked?
2-122 Service Manual
3
Check the sensor (ADF media exit) for proper connection.
Is the above component properly connected?
Replace the
sensor (ADF
media exit).
Replace the
connection.
Go to “Sensor
(standard bin
exit) actuator
assembly
removal” on
page 4-89 or
“Sensor (ADF
media exit)
bracket
assembly
removal (X651)”
on page 4-90.
4
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 5.
5
Perform a print test using the ADF.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF media exit) late jam service check
Use this procedure for the following jams:
• 294.01
Step
1
Check
Check the original document condition.
Yes
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.
Go to step 3.
Clean or replace
the ADF feed/pick
roll assembly or
the ADF
separation roll
assembly.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
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?
No
Go to “ADF feed /
pick roll
assembly
removal” on
page 4-61 or
“ADF separator
torque limiter
assembly
removal” on
page 4-63.
Diagnostic information
2-123
Step
3
Check
Check the media path for contaminates.
Yes
Go to step 4.
Remove all
contaminates from
the media path.
Go to step 6.
Go to step 5.
Replace the
sensor (ADF
media exit).
Replace the
connection.
Is the media path free of excess media dust and foreign
objects such as paper clips and staples?
4
Check the sensor (ADF media exit) for proper operation.
No
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 time
the sensing area of the above sensor is interrupted or
blocked?
5
Check the sensor (ADF media exit) for proper connection.
Is the above component properly connected?
Go to “Sensor
(standard bin
exit) actuator
assembly
removal” on
page 4-89 or
“Sensor (ADF
media exit)
bracket
assembly
removal (X651)”
on page 4-90
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.
Go to “ADF
transport drive
motor bracket
assembly w/
cable removal”
on page 4-77.
7
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 8.
8
Perform a print test using the ADF.
Does the problem remain?
2-124 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Sensor (ADF media exit) lingering jam service check
Use this procedure for the following jams:
• 294.03
Step
1
Check
Check the original document condition.
Yes
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.
Go to step 3.
Clean or replace
the ADF feed/pick
roll assembly or
the ADF
separation roll
assembly.
Is the original document free of paper clips and staples as
well as damage such as creases, tears, holes or excessive
wear?
2
Check the ADF rolls for wear.
No
Is the ADF feed/pick roll assembly or the ADF separation
roll guide assembly free of excess wear?
Go to “ADF feed /
pick roll
assembly
removal” on
page 4-61 or
“ADF separator
torque limiter
assembly
removal” on
page 4-63.
3
Check the media path for contaminates.
Go to step 4.
Remove all
contaminates from
the media path.
Go to step 6.
Go to step 5.
Replace the
sensor (ADF
media exit).
Replace the
connection.
Is the media path free of excess media dust and foreign
objects such as paper clips and staples?
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 time
the sensing area of the above sensor is interrupted or
blocked?
5
Check the sensor (ADF media exit) for proper connection.
Is the above component properly connected?
Go to “Sensor
(standard bin
exit) actuator
assembly
removal” on
page 4-89 or
“Sensor (ADF
media exit)
bracket
assembly
removal (X651)”
on page 4-90.
Diagnostic information
2-125
Step
6
Check
Check the ADF transport drive motor assembly for proper
connection.
Is the above component properly connected?
Yes
Replace the ADF
transport drive
motor assembly.
No
Replace the
connection.
Go to “ADF
transport drive
motor bracket
assembly w/
cable removal”
on page 4-77.
7
Place an undamaged document in the ADF, and perform a
ADF test.
Does the error remain?
Replace the ADF
controller card
assembly.
Problem solved.
Go to “ADF
controller card
removal” on
page 4-67.
Go to step 8.
8
Perform a print test using the ADF.
Does the problem remain?
2-126 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Sensor (input) late jam service check
Use this procedure for the following jams:
• 200.07
• 230.04
• 230.06
• 237.00
• 239.11
• 241.06
• 214.10
• 241.11
• 241.12
• 241.14
• 241.15
• 241.16
• 241.18
• 242.09
• 250.03
• 250.06
• 250.07
• 250.08
• 250.09
• 250.10
• 250.11
• 260.07
• 260.10
• 260.11
• 260.12
• 260.14
• 260.15
• 260.16
Step
1
Check
Check the media size setup and tray guides for all media
trays.
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Remove any
excess new
media.
Go to step 3
Replace the
damaged media
with new.
Go to step 4.
Go to step 5.
Remove
obstructions.
Go to step 6.
Go to step 8.
Go to step 7.
Clean or replace
the MPF pick roll
assembly.
Does the media size, in use, match the size set for all media
trays?
2
Check the media trays for overfilling.
Are any of the media trays overfilled?
3
Check the media condition in all media trays.
Is any of the media in any of the media trays crumpled or
damaged?
4
Check the media tray pass through areas for obstructions.
Are the pass through areas in all the media trays free from
obstructions?
5
Check media origination.
No
Did the media originate from the MPF?
6
Check the MPF pick roll assembly.
Is the above component free of excess wear and
contamination?
Go to “MPF
pick roll
assembly
removal” on
page 4-26.
7
Perform a MPF print test and check the MPF pick solenoid
for proper operation.
Go to step 17.
Does the above component operate properly?
8
Check media origination.
Replace the MPF
pick solenoid.
Go to “MPF pick
solenoid
assembly
removal” on
page 4-26.
Go to step 9
Go to step 13
Go to step 10
Remove
obstructions.
Did the media originate from the internal duplex?
9
Check the internal duplex media path for obstructions.
Is the above component free from obstructions?
Diagnostic information
2-127
Step
10
Check
Check the sensor (duplex input) for proper operation.
Yes
No
Go to step 12.
Go to step 11.
Replace the
Sensor (duplex
input).
Replace the
connection.
1. Enter the diagnostic mode
2. Select Duplex tests
3. Select sensor test
4. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
11
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(duplex input)
removal” on
page 4-41.
12
Perform a print test and check the duplex drive motor
assembly for proper operation.
Go to step 17.
Does the above component operate properly?
Replace the
duplex drive motor
assembly.
Go to “Duplex
drive motor
assembly
removal” on
page 4-9.
13
Check media origination.
Go to step 14.
Go to step 16.
Go to step 15.
Replace the
external duplex
assembly.
Go to step 17.
Replace the
external duplex
assembly.
Go to step 17.
Clean or replace
the pick roll
assembly.
Did the media originate from the external duplex?
14
Check the sensor (duplex input) for proper operation.
1. Enter the diagnostic mode
2. Select 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.
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 display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
16
Check the two pick roll assemblies in the media tray being
picked from.
Are the above components free of excess wear and
contamination?
17
Check the aligner assembly for obstructions.
Is the above component free from obstructions?
2-128 Service Manual
Go to “Pick roll
assembly
removal” on
page 4-31.
Go to step 18.
Remove
obstructions.
Step
18
Check
Yes
Check the sensor (input) for proper operation.
1. Enter the diagnostic mode
The sensor is
working properly.
No
Go to step 19.
Go to step 20.
2. Select Base sensor test
3. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
19
Check the above sensor for proper connection.
Is the above sensor connected properly?
Replace the
Sensor (input).
Replace the
connection.
Go to “Sensor
(input) removal”
on page 4-42.
20
Perform a print test and check the pick arm assembly.
Go to step 21.
Replace the pick
arm assembly. Go
to “Pick arm
assembly
removal” on
page 4-29.
Go to step 22.
Replace the main
drive motor
assembly. Go to
“Main drive
motor assembly
removal” on
page 4-20.
Contact next
highest level of
tech support.
Problem solved.
Is the media properly picked and advanced out of the media
tray?
21
Perform a print test and check the main motor assembly.
Is the media properly transported and able to reach the
sensor (input)?
22
Perform a print test.
Does the problem remain?
Sensor (input) lingering jam service check
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
1
Check
Check the media size setup and tray guides for all media
trays.
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Remove
obstructions.
Go to step 3.
Go to step 4.
Replace the fuser
unit assembly.
Does the media size, in use, match the size set for all
media trays?
2
Check the fuser unit assembly for obstructions.
Is the above component free of obstructions?
3
Check the fuser unit assembly for excess wear and
damage.
Is the above component free of excess wear and
damage?
No
Go to “Fuser unit
assembly
removal” on
page 4-15.
Diagnostic information
2-129
Step
4
Check
Yes
Check the sensor (input) for proper operation.
No
Go to step 6.
Go to step 5.
Replace the
sensor (input).
Replace the
connection.
1. Enter the diagnostic mode
2. Select Base sensor test
3. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
5
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(input) removal”
on page 4-42.
6
Check the sensor (fuser output) for proper operation.
Go to step 8.
Go to step 7.
Replace the fuser
unit assembly.
Replace the
connection.
1. Enter the diagnostic mode
2. Select Base sensor test
3. Observe the line item “exit”
Caution: The area around the actuator is very hot. Allow
the fuser area to cool before proceeding.
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
7
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
8
Perform a print test and check the main motor assembly.
Is the media properly transported and able to reach the
sensor (fuser output)?
Replace the main
drive motor
assembly.
Replace the
connection.
Go to “Main drive
motor assembly
removal” on
page 4-20.
9
Check the aligner assembly for obstructions.
Go to step 10.
Remove
obstructions.
Contact next
highest level of
tech support.
Problem solved.
Is the above component free from obstructions?
10
Perform a print test.
Does the problem remain?
Sensor (input) early jam service check
Use this procedure for the following jams:
• 200.04
2-130 Service Manual
• 200.06
• 200.08
• 200.14
• 200.33
Step
1
Check
Check media origination.
Yes
No
Go to step 2.
Go to step 5.
Go to step 3.
Clean or replace
the MPF pick roll
assembly.
Did the media originate from the MPF?
2
Check the MPF pick roll assembly.
Is the above component free of excess wear and
contamination?
Go to Go to Go to
“MPF pick roll
assembly
removal” on
page 4-26.
3
Perform a MPF print test and check the MPF pick solenoid
for proper operation.
Go to step 4.
Does the above component operate properly?
4
Check the MPF lift plate assembly for damage.
Replace the MPF
pick solenoid.
Go to “MPF pick
solenoid
assembly
removal” on
page 4-26.
Go to step 5.
Is the above component free from damage?
Replace the MPF
lift plate assembly.
Go to “MPF lift
plate assembly
removal” on
page 4-25.
5
Check all the media trays for proper media installation.
Go to step 6.
Remove and
properly re-install
the media.
Go to step 7.
Remove any prestaged or jammed
media.
Go to step 9.
Go to step 8.
Replace the
Sensor (input).
Replace the
connection.
Is the media properly installed in all the media trays?
6
Check all of 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?
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 the above sensor is interrupted or
blocked.
8
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(input) removal”
on page 4-42.
9
Perform a print test.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Sensor (input) static jam service check
Use this procedure for the following jams:
• 200.13
Diagnostic information
2-131
Step
1
Check
Yes
Check the media path for partially fed or jammed media.
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 4.
Go to step 3.
Replace the
Sensor (input).
Replace the
connection.
Is the media path free from partially fed or jammed media?
2
Check the sensor (input) for proper operation.
No
1. Enter the diagnostic mode
2. Select Base sensor test
3. 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.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(input) removal”
on page 4-42.
4
Perform a print test.
Contact next
highest level of
tech support.
Does the problem remain?
Problem solved.
Sensor (fuser output) late jam service check
Use this procedure for the following jams:
• 201.02
• 201.07
• 201.27
• 201.32
• 201.50
• 201.52
• 201.57
• 201.75
• 201.77
• 201.82
Step
1
Check
Check the media size setup and tray guides for all media
trays.
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Go to step 3.
Remove and
properly re-install
the media.
Check the fuser unit assembly for damage and life
expiration.
Replace the fuser
unit assembly.
Go to step 4.
Is the above component damaged or has it exceeded life?
Go to “Fuser unit
assembly
removal” on
page 4-15.
Check the fuser unit assembly for obstructions.
Go to step 5.
Remove
obstructions.
Go to step 7.
Go to step 6.
Does the media size, in use, match the size set for all media
trays?
2
Check all the media trays for proper media installation.
Is the media properly installed in all the media trays?
3
4
Is the above component free from obstructions?
5
No
Check the sensor (fuser output) for proper operation.
1. Enter the diagnostic mode
2. Select Base sensor tests
3. Observe the line item “output”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
2-132 Service Manual
Step
6
Check
Yes
Check the above sensor for proper connection.
Is the above sensor connected properly?
Replace the fuser
unit assembly.
No
Replace the
connection.
Go to “Fuser unit
assembly
removal” on
page 4-15.
7
Check the aligner assembly for obstructions.
Go to step 8.
Remove
obstructions.
Go to step 9.
Replace the
transfer roll
assembly.
Is the above component free from obstructions?
8
Check the transfer roll assembly for damage.
Is the above component free from damage?
Go to “Transfer
roll assembly
removal” on
page 4-56.
9
Perform a print test and check the main motor assembly.
Go to step 10.
Is the media properly transported and able to reach the
sensor (fuser output)?
Replace the main
drive motor
assembly.
Go to “Main drive
motor assembly
removal” on
page 4-20.
10
Perform a print test.
Contact next
highest level of
tech support.
Does the problem remain?
Problem solved.
Sensor (fuser output) lingering jam service check
Use this procedure for the following jams:
• 202.01
• 202.02
• 202.07
• 202.10
• 202.11
• 202.12
• 202.26
• 202.27
• 202.32
• 202.34
• 202.35
• 202.36
• 202.37
• 202.51
• 202.52
• 202.57
• 202.59
• 202.60
• 202.61
• 202.62
• 202.76
• 202.77
• 202.82
• 202.84
• 202.85
• 202.86
• 202.87
Step
1
Check
Check the media size setup and tray guides for all media
trays.
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Go to step 3.
Remove and
properly re-install
the media.
Go to step 4.
Open then
properly close the
door assembly,
rear.
Does the media size, in use, match the size set for all media
trays?
2
Check all the media trays for proper media installation.
Is the media properly installed in all the media trays?
3
Check the door assembly, rear.
Is the above component properly closed?
No
Diagnostic information
2-133
Step
4
5
Check
Yes
No
Check the fuser unit assembly for damage and life
expiration.
Replace the fuser
unit assembly.
Go to step 5.
Is the above component damaged or has it exceeded life?
Go to “Fuser unit
assembly
removal” on
page 4-15.
Check the sensor (fuser output) for proper operation.
Go to step 7.
Go to step 6.
Replace the fuser
unit assembly.
Replace the
connection.
1. Enter the diagnostic mode
2. Select Base sensor tests
3. Observe the line item “output”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
6
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
7
Check the redrive assembly for damage.
Go to step 8.
Is the above component free from damage?
Replace the
redrive assembly.
Go to “Redrive
assembly
removal” on
page 4-60.
8
Perform a print test and check the redrive motor assembly
for proper operation.
Go to step 9.
Does the above component operate properly?
Replace the
redrive motor
assembly.
Go to “Redrive
motor assembly
removal” on
page 4-38.
9
Perform a print test.
Does the problem remain?
2-134 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Sensor (fuser output) static jam service check
Use this procedure for the following jams:
• 202.06
• 202.13
• 202.31
• 202.63
• 202.81
• 202.88
Step
1
• 202.38
Check
• 202.56
Yes
Check the media path for partially fed or jammed media.
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 4.
Go to step 3.
Replace the fuser
unit assembly.
Replace the
connection.
Is the media path free from partially fed or jammed media?
2
Check the sensor (fuser output) for proper operation.
No
1. Enter the diagnostic mode
2. Select Base sensor test
3. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
4
Perform a print test.
Contact next
highest level of
tech support.
Does the problem remain?
Problem solved.
Sensor (narrow media) late jam service check
Use this procedure for the following jams:
• 201.04
• 201.06
• 201.29
• 201.56
• 201.79
• 201.81
Step
1
Check
Check the media size setup and tray guides for all media
trays.
• 201.31
• 201.54
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Go to step 3.
Remove and
properly re-install
the media.
Check the fuser unit assembly for damage and life
expiration.
Replace the fuser
unit assembly.
Go to step 4.
Is the above component damaged or has it exceeded life?
Go to “Fuser unit
assembly
removal” on
page 4-15.
Check the fuser unit assembly for obstructions.
Go to step 5.
Does the media size, in use, match the size set for all media
trays?
2
Check all the media trays for proper media installation.
Is the media properly installed in all the media trays?
3
4
No
Is the above component free from obstructions?
Remove
obstructions.
Diagnostic information
2-135
Step
5
Check
Yes
Check the sensor (narrow media) for proper operation.
No
Go to step 7.
Go to step 6.
Replace the fuser
unit assembly.
Replace the
connection.
1. Enter the diagnostic mode
2. Select Base sensor tests
3. Observe the line item “output”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
6
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
7
Check the aligner assembly for obstructions.
Go to step 8.
Remove
obstructions.
Go to step 9.
Replace the
transfer roll
assembly.
Is the above component free from obstructions?
8
Check the transfer roll assembly for damage.
Is the above component free from damage?
Go to “Transfer
roll assembly
removal” on
page 4-56.
9
Perform a print test and check the main motor assembly.
Go to step 10.
Is the media properly transported and able to reach the
sensor (fuser output)?
Replace the main
drive motor
assembly.
Go to “Main drive
motor assembly
removal” on
page 4-20.
10
Perform a print test.
Contact next
highest level of
tech support.
Does the problem remain?
Problem solved.
Sensor (narrow media) static jam service check
Use this procedure for the following jams:
• 202.03
• 202.13
• 202.28
• 202.63
• 202.78
• 202.88
Ste
p
1
Check
Check the media path for partially fed or jammed media.
Is the media path free from partially fed or jammed media?
2-136 Service Manual
• 202.38
Yes
Go to step 2.
• 202.53
No
Remove any prestaged or jammed
media.
Ste
p
2
Check
Check the sensor (narrow media) for proper operation.
Yes
No
Go to step 4.
Go to step 3.
Replace the fuser
unit assembly.
Replace the
connection.
1. Enter the diagnostic mode
2. Select Base sensor test
3. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Fuser unit
assembly
removal” on
page 4-15.
4
Perform a print test.
Contact next
highest level of
tech support.
Does the problem remain?
Problem solved.
Sensor (duplex input) late jam service check
Use this procedure for the following jams:
• 230.02
• 231.00
Step
1
Check
Check the door assembly, rear.
Yes
Go to step 2.
Open then
properly close the
door assembly,
rear.
Go to step 3.
Open then
properly close the
fuser access door.
Go to step 4
Go to step 10
Go to step 5
Remove
obstructions.
Go to step 6
Replace the
redrive assembly.
Is the above component properly closed?
2
Check the fuser access door.
Is the above component properly closed?
3
Check media origination.
No
Did the media originate from the internal duplex?
4
Check the internal duplex media path for obstructions.
Is the above component free from obstructions?
5
Check the redrive assembly for damage.
Is the above component free from damage?
Go to “Redrive
assembly
removal” on
page 4-60.
6
Perform a print test and check the redrive motor assembly
for proper operation.
Does the above component operate properly?
Go to step 7.
Replace the
redrive motor
assembly.
Go to “Redrive
motor assembly
removal” on
page 4-38.
Diagnostic information
2-137
Step
7
Check
Perform a print test and check the duplex drive motor
assembly for proper operation.
Yes
Go to step 8
Does the above component operate properly?
No
Replace the
duplex drive motor
assembly.
Go to “Duplex
drive motor
assembly
removal” on
page 4-9.
8
Check the sensor (duplex input) for proper operation.
Go to step 10.
Go to step 9.
Replace the
Sensor (duplex
input).
Replace the
connection.
1. Enter the diagnostic mode
2. Select Duplex tests
3. Select sensor test
4. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
9
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(duplex input)
removal” on
page 4-41.
10
Perform a print test and check the duplex drive motor
assembly for proper operation.
Go to step 14.
Does the above component operate properly?
Replace the
duplex drive motor
assembly.
Go to “Duplex
drive motor
assembly
removal” on
page 4-9.
11
Check the external duplex media path for obstructions.
Go to step 12
Remove
obstructions.
Go to step 13.
Remove then
properly re-install
the external
duplex unit
assembly.
Go to step 14.
Replace the
external duplex
assembly.
Contact next
highest level of
tech support.
Problem solved.
Is the above component free from obstructions?
12
Check the external duplex unit assembly for proper
installation.
Is the above component properly installed?
13
Check the sensor (duplex input) for proper operation.
1. Enter the diagnostic mode
2. Select 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.
14
Perform a print test using the duplex.
Does the problem remain?
2-138 Service Manual
Sensor (duplex input) lingering jam service check
Use this procedure for the following jams:
• 230.01
• 230.05
Step
1
• 232.00
Check
Check media origination.
Yes
No
Go to step 2
Go to step 7
Go to step 3
Remove
obstructions.
Go to step 4.
Replace the
duplex guide
assembly, front.
Did the media originate from the internal duplex?
2
Check the internal duplex media path for obstructions.
Is the above component free from obstructions?
3
Check the duplex guide assembly, front for damage.
Is the above component free from damage?
Go to “Duplex
guide assembly,
front removal” on
page 4-10.
4
Check the sensor (duplex input) for proper operation.
Go to step 6.
Go to step 5.
Replace the
sensor (duplex
input).
Replace the
connection.
1. Enter the diagnostic mode
2. Select Duplex tests
3. Select sensor test
4. 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.
5
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(duplex input)
removal” on
page 4-41.
6
Check the aligner assembly for obstructions.
Go to step 7.
Remove
obstructions.
Go to step x
Remove
obstructions.
Go to step 9.
Remove then
properly re-install
the external
duplex unit
assembly.
Go to step 10.
Replace the
external duplex
assembly.
Is the above component free from obstructions?
7
Check the external duplex media path for obstructions.
Is the above component free from obstructions?
8
Check the external duplex unit assembly for proper
installation.
Is the above component properly installed?
9
Check the sensor (duplex input) for proper operation.
1. Enter the diagnostic mode
2. Select 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.
Diagnostic information
2-139
Step
10
Check
Yes
Perform a print test using the duplex.
Contact next
highest level of
tech support.
Does the problem remain?
No
Problem solved.
Sensor (duplex input) static jam service check
Use this procedure for the following jams:
• 230.13
• 238.01
Step
1
• 238.03
Check
Check media origination.
• 238.05
• 238.07
Yes
No
Go to step 2
Go to step 5
Go to step 3.
Remove any prestaged or jammed
media.
Go to step 7.
Go to step 4.
Replace the
sensor (duplex
input).
Replace the
connection.
Did the media originate from the internal duplex?
2
Check the media path for partially fed or jammed media.
Is the media path free from partially fed or jammed media?
3
Check the sensor (duplex input) for proper operation.
1. Enter the diagnostic mode
2. Select Duplex tests
3. Select sensor test
4. Observe the line item “input”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(duplex input)
removal” on
page 4-41.
5
Check the media path for partially fed or jammed media.
Go to step 6.
Remove any prestaged or jammed
media.
Go to step 7.
Replace the
external duplex
assembly.
Contact next
highest level of
tech support.
Problem solved.
Is the media path free from partially fed or jammed media?
6
Check the sensor (duplex input) for proper operation.
1. Enter the diagnostic mode
2. Select 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.
7
Perform a print test using the duplex.
Does the problem remain?
2-140 Service Manual
Sensor (pass through) late jam service check
Use this procedure for the following jams:
• 242.02
• 242.03
• 242.04
• 242.05
• 242.06
• 242.10
• 242.16
• 242.37
• 243.02
• 243.03
• 243.04
• 243.04
• 243.05
• 243.06
• 243.10
• 243.16
• 243.37
• 244.02
• 244.03
• 244.04
• 244.05
• 244.06
• 244.10
• 244.16
• 244.37
• 245.02
• 245.03
• 245.04
• 245.05
• 245.06
• 245.10
• 245.13
• 245.16
• 245.37
Step
1
Check
Check the media size setup and tray guides for all media
trays.
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Remove any
excess new
media.
Go to step 3
Replace the
damaged media
with new.
Go to step 4.
Go to step 5.
Remove
obstructions.
Go to step 6.
Clean or replace
the pick roll
assembly.
Does the media size, in use, match the size set for all media
trays?
2
Check the media trays for overfilling.
Are any of the media trays overfilled?
3
Check the media condition in all media trays.
Is any of the media in any of the media trays crumpled or
damaged?
4
Check the media tray pass through areas for obstructions.
Are the pass through areas in all the media trays free from
obstructions?
5
Check the two pick roll assemblies in the media tray being
picked from.
Are the above components free of excess wear and
contamination?
6
Check the appropriate media tray sensor (pass through) for
proper operation.
No
Go to “Pick roll
assembly
removal” on
page 4-31.
Go to step 7.
Go to step 6.
Replace the
appropriate
Sensor (pass
through).
Replace the
connection.
1. Enter the diagnostic mode
2. Select Input tray tests
3. Sensor test
4. Select the appropriate tray number
3. Observe the line item “pass through” for the appropriate
media tray
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
7
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(pass through)
with cable
removal” on
page 4-198.
Diagnostic information
2-141
Step
8
Check
Yes
Perform a print test and check the pick arm assembly for
the appropriate media tray.
Go to step 8.
Is the media properly picked and advanced out of the
appropriate media tray?
9
Perform a print test and check the main motor assembly.
No
Replace the
appropriate pick
arm assembly.
Go to “Pick arm
assembly
removal” on
page 4-29.
Go to step 9.
Is the media properly transported through the pass through
areas of the media trays?
Replace the main
drive motor
assembly.
Go to “Main drive
motor assembly
removal” on
page 4-20.
10
Perform a print test using the appropriate input tray.
Does the error continue?
Replace the input
option.
Problem solved.
Sensor (pass through) lingering jam service check
Use this procedure for the following jams:
• 242.08
• 242.40
• 243.08
• 244.40
• 245.08
• 245.40
Step
1
Check
Check the media size setup and tray guides for all media
trays.
• 243.40
244.08
Yes
Go to step 2.
Replace the
media, or change
the media size
setup.
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Does the media size, in use, match the size set for all media
trays?
2
Check the media tray pass through areas for obstructions.
Are the pass through areas in all the media trays free from
obstructions?
3
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 sensing area of the above sensor is interrupted or
blocked.
2-142 Service Manual
No
Step
4
Check
Yes
Check the above sensor for proper connection.
Is the above sensor connected properly?
Replace the
appropriate
Sensor (pass
through).
No
Replace the
connection.
Go to “Sensor
(pass through)
with cable
removal” on
page 4-198.
5
Perform a print test and check the main motor assembly.
Is the media properly transported through the pass through
areas of the media trays?
Replace the main
drive motor
assembly.
Replace the
connection.
Go to “Main drive
motor assembly
removal” on
page 4-20.
6
Perform a print test using the appropriate input tray.
Does the error continue?
Replace the input
option.
Problem solved.
Sensor (pass through) static jam service check
Use this procedure for the following jams:
• 242.13
• 242.36
• 243.13
• 244.36
• 245.13
• 245.36
Step
1
Check
Check the media path for partially fed or jammed media.
• 243.36
244.13
Yes
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 5.
Go to step 4.
Replace the
appropriate sensor
(pass through).
Replace the
connection.
Is the media path free from partially fed or jammed media?
2
Check the appropriate media tray sensor (pass through) for
proper operation.
No
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 sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(pass through)
with cable
removal” on
page 4-198.
4
Perform a print test using the appropriate input tray.
Does the error continue?
Replace the input
option.
Problem solved.
Diagnostic information
2-143
Sensor (stapler pass through) late jam service check
Step
1
Check
Check the output option for proper installation.
Yes
Go to step 2.
Remove then
reinstall the output
option
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the output
option.
Replace the
connection.
Is the above component properly installed?
2
Check for obstructions in the media path between the base
machine and the output option.
No
Is the media path free from obstructions?
3
Check the sensor (stapler pass through) for proper
operation.
1. Enter the diagnostic mode
2. Select Finisher sensor test
3. Select Sensor test
4. Select pass & media
5. Observe the line item “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Sensor (stapler pass through) lingering jam service check
Step
1
Check
Check the output option for proper installation.
Yes
Go to step 2.
Remove then
reinstall the output
option
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the output
option.
Replace the
connection.
Is the above component properly installed?
2
Check for obstructions in the media path between the
Sensor (stapler pass through) machine and the media bin.
No
Is the media path free from obstructions?
3
Check the sensor (stapler pass through) for proper
operation.
1. Enter the diagnostic mode
2. Select Finisher sensor test
3. Select Sensor test
4. Select pass & media
5. Observe the line item “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
2-144 Service Manual
Sensor (stapler pass through) static jam service check
Step
1
Check
Check the media path for partially fed or jammed media.
Yes
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 4.
Go to step 3.
Replace the output
option.
Replace the
connection.
Is the media path free from partially fed or jammed media?
2
Check the sensor (stapler pass through) for proper
operation.
No
1. Enter the diagnostic mode
2. Select Finisher sensor test
3. Select Sensor test
4. Select pass & media
5. Observe the line item “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Sensor (output pass through) late jam service check
Step
1
Check
Check the output option for proper installation.
Yes
Go to step 2.
Remove then
reinstall the output
option
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the
sensor (output
pass through).
Replace the
connection.
Is the above component properly installed?
2
Check for obstructions in the media path between the base
machine and the output option.
No
Is the media path free from obstructions?
3
Check the sensor (output pass through) 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 “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “4-bin
mailbox
assembly sensor
(pass through)
removal” on
page 4-232.
5
Perform a print test using the output option.
Does the error continue?
Replace the output
option.
Problem solved.
Diagnostic information
2-145
Sensor (output pass through) lingering jam service check
Step
1
Check
Check the output option for proper installation.
Yes
Go to step 2.
Remove then
reinstall the output
option
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the
sensor (output
pass through).
Replace the
connection.
Is the above component properly installed?
2
Check for obstructions in the media path between the
Sensor (output pass through) machine and the media bin.
No
Is the media path free from obstructions?
3
Check the sensor (output pass through) 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 “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “4-bin
mailbox
assembly sensor
(pass through)
removal” on
page 4-232.
5
Perform a print test using the output option.
Does the error continue?
Replace the output
option.
Problem solved.
Sensor (output pass through) static jam service check
Ste
p
1
Check
Check the media path for partially fed or jammed media.
Yes
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 4.
Go to step 3.
Is the media path free from partially fed or jammed media?
2
Check the sensor (output pass through) 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 “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
2-146 Service Manual
No
Ste
p
3
Check
Check the above sensor for proper connection.
Is the above sensor connected properly?
Yes
Replace the
sensor (output
pass through).
No
Replace the
connection.
Go to “4-bin
mailbox
assembly sensor
(pass through)
removal” on
page 4-232.
4
Perform a print test using the output option.
Does the error continue?
Replace the output
option.
Problem solved.
Sensor (mailbox empty) late jam service check
Step
1
Check
Check the output option for proper installation.
Yes
Go to step 2.
Remove then
reinstall the output
option
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the
sensor (mailbox
empty).
Replace the
connection.
Is the above component properly installed?
2
Check for obstructions in the media path between the base
machine and the output option.
No
Is the media path free from obstructions?
3
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.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “4-bin
mailbox
assembly sensor
(mailbox empty)
removal” on
page 4-233.
5
Perform a print test using the output option.
Does the error continue?
Replace the output
option.
Problem solved.
Sensor (mailbox empty) lingering jam service check
Step
1
Check
Check the output option for proper installation.
Is the above component properly installed?
Yes
Go to step 2.
No
Remove then
reinstall the output
option
Diagnostic information
2-147
Step
2
Check
Check for obstructions in the media path between the
Sensor (mailbox empty) machine and the media bin.
Yes
No
Go to step 3.
Remove
obstructions.
Go to step 5.
Go to step 4.
Replace the
sensor (mailbox
empty).
Replace the
connection.
Is the media path free from obstructions?
3
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.
4
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “4-bin
mailbox
assembly sensor
(mailbox empty)
removal” on
page 4-233.
5
Perform a print test using the output option.
Does the error continue?
Replace the output
option.
Problem solved.
Sensor (mailbox empty) static jam service check
Step
1
Check
Check the media path for partially fed or jammed media.
Yes
Go to step 2.
Remove any prestaged or jammed
media.
Go to step 4.
Go to step 3.
Replace the
sensor (mailbox
empty).
Replace the
connection.
Is the media path free from partially fed or jammed media?
2
Check the sensor (mailbox empty) for proper operation.
No
1. Enter the diagnostic mode
2. Select Output bin tests
3. Select Sensor test
4. Select Output bin x
5. Observe the line item “passthru”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked.
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “4-bin
mailbox
assembly sensor
(mailbox empty)
removal” on
page 4-233.
4
Perform a print test using the output option.
Does the error continue?
2-148 Service Manual
Replace the output
option.
Problem solved.
Sensor (toner empty) service check
Step
1
Check
Check the sensor (toner empty) for proper installation.
Yes
go to step 2.
Reinstall the
sensor (toner
empty)
The sensor is
working properly.
Go to step 3.
Replace the
sensor (toner
empty).
Replace the
connection.
Is the above component properly installed?
2
Check the sensor (toner empty) for proper operation.
1. Enter the diagnostic mode
No
2. Select Base sensor test
3. Observe the line item “toner empty”
Does the display on the operator panel, change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(toner empty)
removal” on
page 4-41.
Sensor (scanner HP) service check
Step
1
Check
Check the sensor (scanner HP) for proper installation.
Yes
Go to step 2.
Reinstall the
sensor (scanner
HP)
The sensor is
working properly.
Go to step 3.
Replace the
sensor (scanner
HP).
Replace the
connection.
Is the above component properly installed?
2
Check the sensor (scanner HP) for proper operation.
1. Enter the diagnostic mode
No
2. Select Scanner tests
3. Select Sensor tests
4. Observe the line item “Scanner HP”
Does the display on the operator panel change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(scanner HP)
assembly w/
bracket removal”
on page 4-154.
Sensor (ADF 2nd scan) late jam service check
Step
Check
Yes
No
Diagnostic information
2-149
1
Check the sensor (ADF 2nd scan) for proper installation.
Go to step 2.
Reinstall the
sensor (ADF 2nd
scan)
The sensor is
working properly.
Go to step 3.
Replace the
sensor (ADF 2nd
scan).
Replace the
connection.
Is the above component properly installed?
2
Check the sensor (ADF 2nd scan) for proper operation.
1. Enter the diagnostic mode
2. Select Scanner tests
3. Select Sensor tests
4. Observe the line item “ADF 2nd scan”
Does the display on the operator panel change every time
the sensing area of the above sensor is interrupted or
blocked?
3
Check the above sensor for proper connection.
Is the above sensor connected properly?
Go to “Sensor
(ADF 2nd scan)
removal” on
page 4-81.
NVRAM mismatch failure (950.00 through 950.29) service check
Warning: When replacing any of the following components:
• Scanner interface card assembly
• System card assembly
Only replace one component at a time. replace the required component and perform a POR before replacing
a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Never replace two or more of the components listed above without a POR after installing each one or the
printer will be rendered inoperable.
Warning: These components 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.
Step
1
Check
Check the operator panel assembly.
Yes
No
Go to step 3.
Go to step 2.
Go to step 4.
Contact next level
of support.
Go to step 5.
Problem solved.
Go to step 6.
Problem solved.
Contact the next
level of support.
Problem solved.
Contact the next
level of support.
Problem solved.
Was the operator panel assembly recently replaced?
2
Check the system card assembly.
Was the system card assembly recently replaced?
3
Replace the current operator panel assembly with the
original operator panel assembly.
Does the error remain?
4
Replace the current system card assembly with the original
system card assembly.
5
If problem continues, replace the original operator panel
assembly with a new and not previously installed operator
panel assembly.
Go to “System card assembly removal” on page 4-50.
Does the error continue?
6
If the problem continues, replace the original panel
assembly with a new ann not previously installed operator
panel door assembly or the operator panel assembly.
Go to “USB cable removal (model X658)” on page 4-114.
Go to “Operator panel assembly removal (model X658)”
on page 4-109.
2-150 Service Manual
Image quality trouble
Printer Related Troubleshooting
Note: First, get a printout as a base, and follow the symptom table to identify the possible failing FRU’s.
Image quality symptoms
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Faint print (low contrast)— “Faint print (Low contrast)” on page 2-152.
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.
Horizontal stripes— “Horizontal stripes (side to side direction)” on page 2-160.
Partial lack— “Partial lack” on page 2-162.
Spots— “Spots” on page 2-163.
Afterimage— “After image” on page 2-165.
Background (fog)— “Background (fog)” on page 2-166.
Skew—“Skew” on page 2-167.
Media damage— “Media damage” on page 2-168.
No fuse—“No fuse” on page 2-170.
Note: When horizontal lines and/or spots occur periodically, it is possibly caused 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.
Diagnostic information
2-151
Image Quality
Faint print (Low contrast)
Leading edge
Trailing edge
Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path.
Step
1
Check
Check the media condition.
Yes
No
Problem solved.
Go to step 2.
Go to step 3.
Replace the
print cartridge.
Go to step 4.
Replace the
transfer roll
assembly.
Load new, dry, recommended media, and perform a print
test.
Is the image density normal?
2
Check the toner level.
Is the toner level normal?
3
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
4
Check the print cartridge for proper installation.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 5.
Inspect, clean
and reinstall
replace the print
cartridge.
Go to step 6.
Remove debris
or clean the
printhead
assembly
window.
Replace the
HVPS card
assembly. Go to
“HVPS card
assembly
removal” on
page 4-17.
Replace the
connections.
Is the print cartridge properly installed?
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?
6
Check the HVPS card assembly for proper connection.
Is the above component properly connected?
2-152 Service Manual
Step
7
Check
Check the printhead assembly for proper connection.
Is the above component properly connected?
Yes
Replace the
printhead
assembly.
No
Replace the
connections.
Go to
“Printhead
assembly
removal” on
page 4-34.
8
Perform a print test.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-153
Blank print (no print)
Check the media path for foreign objects such as staples, clips, scraps of media.
Step
1
Check
Check the media condition.
Yes
No
Problem solved.
Go to step 2.
Go to step 3.
Replace the
print cartridge.
Go to step 4.
Reinstall the
transfer roll
assembly.
Go to step 5.
Replace the left
and or right
transfer roll
brackets.
Load new, dry, recommended media, and perform a
print test.
Is the image density normal?
2
Check the toner level.
Is the toner level normal?
3
Check the transfer roll assembly for proper installation?
Is the above component properly installed?
4
Check the left and right transfer roll bracket.
Are the above components free from damage?
Go to “Transfer
roll bracket
assembly, left
removal” on
page 4-57 and
“Transfer roll
bracket
assembly, right
removal” on
page 4-57.
5
Check the transfer roll assembly for contamination and
wear.
Go to step 6.
Is the above component free of excess wear and
contamination?
6
Check the print cartridge for proper installation.
Is the print cartridge properly installed?
2-154 Service Manual
Replace the
transfer roll
assembly.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 7.
Inspect, clean
and reinstall
replace the print
cartridge.
Step
7
Check
Check the laser beam route.
Yes
Go to step 8.
Remove debris
or clean the
printhead
assembly
window.
Replace the
HVPS card
assembly.
Replace the
connections.
Check for debris between the printhead assembly and
the PC drum.
Is the laser beam route free of debris and the glass
window, in the printhead assembly, free of
contamination?
8
Check the HVPS card assembly for proper connection.
Is the above component properly connected?
No
Go to “HVPS
card assembly
removal” on
page 4-17.
9
Check the printhead assembly for proper connection.
Is the above component properly connected?
Replace the
printhead
assembly.
Replace the
connections.
Go to
“Printhead
assembly
removal” on
page 4-34.
10
Check the system card assembly for proper connection.
Is the above component properly connected?
Replace the
system card
assembly.
Replace the
connections.
Go to “System
card assembly
removal” on
page 4-50.
Diagnostic information
2-155
Solid black
Check the media path for foreign objects such as staples, clips, scraps of media.
Step
1
Check
Check the charge roll assembly for proper installation.
Yes
Go to step 2.
Replace the
charge roll
assembly.
Go to step 3.
Inspect, clean
and reinstall
replace the print
cartridge.
Replace the
HVPS card
assembly.
Replace the
connection.
Is the above component properly installed?
2
Check the print cartridge for proper installation.
Is the above component properly installed?
3
Check the charge roll HVPS card assembly connections
Is the above component properly connected?
No
Go to “HVPS
card assembly
removal” on
page 4-17.
4
Check the system card assembly for proper connection.
Is the above component properly connected?
Replace the
system card
assembly.
Go to “System
card assembly
removal” on
page 4-50.
2-156 Service Manual
Replace the
connections.
Vertical lines and bands (process direction)
Leading edge
Trailing edge
Step
1
Check
Check the media condition.
Yes
No
Go to step 2.
Problem solved.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Is the media transfer route and the media path clear of
debris?
Go to step 3.
Remove debris or
contamination.
3
Check the laser beam route.
Go to step 4.
Remove debris or
clean the
printhead
assembly window.
Go to step 5.
Inspect, clean and
reinstall replace
the print cartridge.
Go to step 6.
Replace the
transfer roll
assembly.
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?
4
Check the print cartridge for proper installation.
Is the above component properly installed?
5
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
6
Check the printhead assembly for proper connection.
Is the above component properly connected?
Go to “Transfer
roll assembly
removal” on
page 4-56.
Replace the
printhead
assembly.
Replace the
connections.
Go to “Printhead
assembly
removal” on
page 4-34.
7
Perform a print test.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-157
Horizontal white stripes or bands (side to side direction)
Leading edge
Trailing edge
Step
1
Check
Check the media condition.
Yes
No
Go to step 2.
Problem solved.
Load new, dry, and recommended media.
Re-print the defective image.
Does the error continue?
2
Are the media transfer route and the media path free of
contamination and debris?
Go to step 3.
Remove debris or
contamination.
3
Check the toner level.
Go to step 4.
Replace the print
cartridge.
Go to step 5.
Replace the
transfer roll
assembly.
Is the toner level normal?
4
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the printhead assembly for proper connection.
Is the above component properly connected?
Go to “Transfer
roll assembly
removal” on
page 4-56.
Replace the
printhead
assembly.
Replace the
connections.
Go to “Printhead
assembly
removal” on
page 4-34.
6
Perform a print test.
Does the problem remain?
2-158 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Vertical stripes (process direction)
Leading edge
Trailing edge
Step
1
Check
Yes
Check the media condition.
No
Go to step 2.
Problem solved.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Are the media transfer route and the media path free of
contamination or debris?
Go to step 3.
Remove debris
or
contamination.
3
Check the charge roll assembly for contamination and
wear.
Go to step 4.
Replace the
charge roll
assembly.
Is the above component free of excess wear and
contamination?
4
Check the transfer roll assembly for contamination and
wear.
Go to “Charge
roll assembly
removal” on
page 4-6.
Go to step 5.
Is the above component free of excess wear and
contamination?
5
Check the print cartridge for proper installation.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 6.
Inspect, clean
and reinstall
replace the print
cartridge.
Replace the
fuser unit
assembly.
Go to step 7.
Is the above component properly installed?
6
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Replace the
transfer roll
assembly.
Go to “Fuser
unit assembly
removal” on
page 4-15.
Is there contamination or cracks on the heat roll and/or
pressure roll?
Diagnostic information
2-159
Step
7
Check
Perform a print test.
Does the problem remain?
Yes
Contact next
highest level of
tech support.
No
Problem solved.
Horizontal stripes (side to side direction)
Leading edge
Trailing edge
Step
1
Check
Check the media condition.
Yes
No
Go to step 2.
Problem solved.
Go to step 3.
Remove
obstacles or
contamination.
Go to step 4.
Inspect, clean
and reinstall
replace the print
cartridge.
Go to step 5.
Replace the
charge roll
assembly.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Check the media transfer route.
Check the media route for contamination or obstacles.
3
Check the print cartridge for proper installation.
Is the above component properly installed?
4
Check the charge roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
2-160 Service Manual
Go to “Charge
roll assembly
removal” on
page 4-6.
Go to step 6.
Replace the
transfer roll
assembly.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Step
6
Check
Yes
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Replace the
fuser unit
assembly.
No
Go to step 7.
Go to “Fuser
unit assembly
removal” on
page 4-15.
Is there contamination or cracks on the heat roll and/or
pressure roll?
7
Check the HVPS card assembly for proper connection.
Is the above component properly connected?
Replace the
HVPS card
assembly.
Replace the
connections.
Go to “HVPS
card assembly
removal” on
page 4-17.
8
Perform a print test.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-161
Partial lack
Leading edge
Trailing edge
Step
1
Check
Check the media condition.
Yes
No
Go to step 2.
Problem solved.
Go to step 3.
Replace the
print cartridge.
Go to step 4.
Remove debris
or clean the
printhead
assembly
window.
Go to step 5.
Replace the
transfer roll
assembly.
Load new, dry, recommended media.
Re-print the defective image.
Does the problem remain?
2
Check the toner level.
Is the toner level normal?
3
Check the laser beam route.
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?
4
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the printhead installation.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 6.
Is the above component properly installed?
Reinstall and
adjust the
printhead
assembly.
Go to
“Printhead
assembly
removal” on
page 4-34.
6
Perform a print test.
Does the problem remain?
2-162 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Spots
Leading edge
Trailing edge
Step
1
Check
Yes
Check the media condition.
No
Go to step 2.
Problem solved.
Go to step 3.
Remove debris
or
contamination.
Go to step 4.
Replace the
print cartridge.
Go to step 5.
Replace the
charge roll
assembly.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Check the media transfer route.
Is the media route free of contamination or debris?
3
Check the print cartridge for spots or other damage on
the drum surfaces.
Is the print cartridges free of excess wear and
contamination?
4
Check the charge roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the transfer roll assembly for contamination and
wear.
Go to “Charge
roll assembly
removal” on
page 4-6.
Go to step 6.
Is the above component free of excess wear and
contamination?
6
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Replace the
transfer roll
assembly.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Replace the
fuser unit
assembly.
Go to step 7
Go to “Fuser
unit assembly
removal” on
page 4-15.
Is there contamination or cracks on the heat roll and/or
pressure roll?
Diagnostic information
2-163
Step
7
Check
Check the printhead installation.
Yes
Go to step 8.
Is the above component properly installed?
No
Reinstall and
adjust the
printhead
assembly.
Go to
“Printhead
assembly
removal” on
page 4-34.
8
Perform a print test.
Does the problem remain?
2-164 Service Manual
Contact next
highest level of
tech support.
Problem solved.
After image
Leading edge
Trailing edge
The ghost appears on the media which, may be the image from the previous page or part of the page
currently printing.
Step
1
Check
Yes
Check the media condition.
No
Go to step 2.
Problem solved.
Replace the
fuser unit
assembly.
Go to step 4.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Go to “Fuser
unit assembly
removal” on
page 4-15.
Is there contamination or cracks on the heat roll and/or
pressure roll?
3
Perform a print test.
Does the problem remain?
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-165
Background (fog)
Leading edge
Trailing edge
Step
1
Check
Check the media condition.
Yes
No
Go to step 2.
Problem solved.
Go to step 3.
Remove debris
or
contamination.
Go to step 4.
Inspect, clean
and reinstall
replace the print
cartridge.
Go to step 5.
Replace the
transfer roll
assembly.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
2
Check the media transfer route.
Is the media path free of contamination or debris.
3
Check the print cartridge for proper installation.
Is the above component properly installed?
4
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the HVPS card assembly for proper connection.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 6.
Replace the
connections.
Go to step 7.
Reinstall and
adjust the
printhead
assembly.
Is the above component connected properly?
6
Check the printhead installation.
Is the above component properly installed?
Go to
“Printhead
assembly
removal” on
page 4-34.
7
Perform a print test.
Does the problem remain?
2-166 Service Manual
Contact next
highest level of
tech support.
Problem solved.
Skew
Leading edge
Trailing edge
The printed image is not paralleled with both sides of the media.
Step
1
Check
Check printer installation placement.
Yes
No
Go to step 2.
Correct the
installation
placement.
Go to step 3.
Problem solved.
Go to step 4.
Remove
obstructions.
Go to step 5.
Replace the
transfer roll
assembly.
Check the installation surface for irregularities.
Check for damaged printer caster.
Is the setup surface normal?
2
Properly load media into the media tray assembly and
ensure all guides are set correctly.
Properly install the media tray assembly into the printer.
Re-print the defective image.
Does the error continue?
3
Check for obstructions in the area of the media feed
units.
Are the media feed unit assembly free from any
obstructions?
4
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the alignment assembly for proper adjustment.
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 6.
Go to “Alignment assembly adjustment” on
page 4-3.
Go to
“Alignment
assembly
removal” on
page 4-21.
Does the problem remain?
6
Perform a print test.
Does the problem remain?
Replace the
aligner
assembly.
Contact next
highest level of
tech support.
Problem solved.
Diagnostic information
2-167
Media damage
Leading edge
Trailing edge
Step
1
Check
Check printer installation placement.
Yes
No
Go to step 2.
Correct the
installation
placement.
Go to step 3.
Problem solved.
Go to step 4.
Problem solved.
Go to step 5.
Replace the
transfer roll
assembly.
Check the installation surface for irregularities.
Check for missing printer foot.
Is the setup surface normal?
2
Check the media feed.
Remove the media tray assembly.
Properly load media in the media tray assembly.
Properly install the media tray assembly in the printer.
Re-print the defective image.
Does the error continue?
3
Check the media condition.
Load new, dry, recommended media.
Re-print the defective image.
Does the error continue?
4
Check the transfer roll assembly for contamination and
wear.
Is the above component free of excess wear and
contamination?
5
Check the alignment assembly for proper adjustment.
Go to “Alignment assembly adjustment” on
page 4-3.
Does the problem remain?
2-168 Service Manual
Go to “Transfer
roll assembly
removal” on
page 4-56.
Go to step 6.
Replace the
alignment
assembly.
Go to Go to
“Alignment
assembly
removal” on
page 4-21.
Step
6
Check
Yes
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Replace the
fuser unit
assembly.
Go to “Fuser
unit assembly
removal” on
page 4-15.
No
Inspect the
machine for
obstructions in
the media path.
Is there contamination or cracks on the heat roll and/or
pressure roll?
Diagnostic information
2-169
No fuse
Leading edge
Trailing edge
Step
1
Check
Yes
Check the fuser unit assembly installation.
Go to step 2.
Reinstall the
fuser unit
assembly.
Go to step 3.
Problem solved.
Replace the
fuser unit
assembly.
Go to step 4.
Is the fuser unit assembly properly installed?
2
Check the media condition.
No
Load new, dry, recommended media.
Re-print the defective image.
Does the problem remain?
3
Check the heat roll and pressure roll.
Remove the fuser unit assembly.
CAUTION: : Allow
the fuser unit
assembly to cool
down.
Go to “Fuser
unit assembly
removal” on
page 4-15.
Is there contamination or cracks on the heat roll and/or
pressure roll?
4
Check the LVPS card assembly for proper connection.
Is the above component connected properly?
Replace the
LVPS card
assembly.
Go to “LVPS
card assembly
removal” on
page 4-47.
5
Perform a print test.
Does the problem remain?
Replace the
system card
assembly.
Go to “System
card assembly
removal” on
page 4-50.
2-170 Service Manual
Remove then
reinsert the
LVPS card
assembly.
Problem solved.
ADF & Scanner Related Troubleshooting
Note: First, get a printout as a base, and follow the symptom table to identify the possible failing FRU’s.
Image quality symptoms:
•
•
•
•
•
•
Dark print — “Faint print (Low contrast)” on page 2-152.
Vertical stripes— “Vertical stripes (process direction)” on page 2-159.
Horizontal stripes— “Horizontal stripes (side to side direction)” on page 2-160.
Spots— “Spots” on page 2-163.
Skew—“Skew” on page 2-167.
Media damage— “Media damage” on page 2-168.
Note: When horizontal lines and/or spots occur periodically, it is possibly caused 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.
Diagnostic information
2-171
ADF & Scanner Image Quality
Dark image quality (using ADF or Scanner)
Leading edge
Trailing edge
Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path.
Step
1
Check
Check the large and small platen glass on the scanner
unit assembly.
Is the large and small platen glass contaminated?
2
Check the three mirrors in the scanner unit assembly.
Are the three mirrors contaminated or show signs of
dust?
3
Check the white strip on the bottom of the large platen
glass.
Is the white strip contaminated?
4
Check the scanner lens.
Is the scanner lens contaminated?
5
Perform a print test using the ADF & scanner unit
assemblies.
Does the error continue?
Yes
No
Clean both sides
of the large and
small platen
glass.
Go to step 2.
Clean the three
mirrors in the
scanner unit
assembly.
Go to step 3.
Clean the white
strip and POR
the machine.
Go to step 4.
Clean the
scanner lens.
Go to step 5.
Replace the
CCD/card lens
assembly.
Problem solved.
Go to
6
Perform a print test using the ADF & scanner unit
assemblies.
Does the error continue?
Replace the
scanner
controller card
assembly.
Go to “Scanner
controller card
assembly
removal
(models X651,
X652/5535dn,
X654, and X656)”
on page 4-132.
2-172 Service Manual
Problem solved.
Vertical lines (process direction using the ADF)
Leading edge
Trailing edge
Step
1
Check
Check the small platen glass on the scanner unit
assembly.
Is the large and small platen glass contaminated or
damaged?
Yes
Clean or replace
the scanner
platen glass
cover.
No
Go to step 2.
Go to “Scanner
platen glass
cover
assembly
removal (model
X658)” on
page 4-139.
2
Check the three mirrors in the scanner unit assembly.
Are the three mirrors contaminated or show signs of
dust?
3
Check the white strip on the bottom of the large platen
glass.
Is the white strip contaminated?
4
Perform a print test using the scanner unit assembly.
Does the error continue?
Clean the three
mirrors in the
scanner unit
assembly.
Go to step 3.
Clean the white
strip and POR
the machine.
Go to step 4.
Replace the
scanner unit
assembly.
Problem solved.
Go to “Scanner
unit assembly
removal
(models X651,
X652/5535dn,
X654, and X656)”
on page 4-94.
Diagnostic information
2-173
Step
5
Check
Perform a print test using the ADF unit assembly.
Does the error continue?
Yes
Replace the
scanner
controller card
assembly.
No
Problem solved.
Go to “Scanner
controller card
assembly
removal
(models X651,
X652/5535dn,
X654, and X656)”
on page 4-132.
Spots (using flatbed scanner)
Leading edge
Trailing edge
Step
1
Check
Check the large platen glass on the scanner unit
assembly.
Is the large platen glass contaminated or damaged?
Yes
Clean or replace
the scanner
platen glass
cover.
No
Go to step 2.
Go to “Scanner
platen glass
cover assembly
removal
(models X651,
X652/5535dn,
X654, and
X656)” on
page 4-140 or
“Scanner
platen glass
cover assembly
removal
(model X658)”
on page 4-139.
2
Check the three mirrors in the scanner unit assembly.
Are the three mirrors contaminated or show signs of
dust?
2-174 Service Manual
Clean the three
mirrors in the
scanner unit
assembly.
Go to step 3.
Step
3
Check
Check the white strip on the bottom of the large platen
glass.
Is the white strip contaminated?
4
Perform a print test using the scanner CCD assembly.
Does the error continue?
Yes
No
Clean the white
strip and POR
the machine.
Go to step 4.
Replace the
scanner CCD
assembly.
Problem solved.
Go to “Scanner
CCD assembly
removal” on
page 4-91.
5
Perform a print test using the flatbed scanner assembly.
Does the error continue?
Replace the
scanner
controller card
assembly.
Problem solved.
Go to “Scanner
controller card
assembly
removal
(models X651,
X652/5535dn,
X654, and X656)”
on page 4-132.
Diagnostic information
2-175
Skew (using ADF)
Leading edge
Trailing edge
The printed image is not paralleled with both sides of the media.
Step
1
Check
Check printer installation placement.
Yes
No
Go to step 2.
Correct the
installation
placement.
Go to step 3.
Problem solved.
Go to step 4.
Remove
obstructions.
Check the installation surface for irregularities.
Check for damaged printer caster.
Is the setup surface normal?
2
Properly load document into the ADF unit assembly and
ensure all guides are set correctly.
Re-print the defective image.
Does the error continue?
3
Check for obstructions in the area of the media feed
path in the ADF.
Is the media feed path free from any 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.
Go to step 6.
Replace the
ADF feed/pick
roll assembly.
Is the ADF feed/pick roll assembly free from damage
and wear?
6
Check the ADF separator roll.
Is the ADF separator roll free from damage and wear?
Go to “ADF
feed / pick roll
assembly
removal” on
page 4-61.
Go to step 7.
Replace the
ADF separation
roll.
Go to “ADF
separator roll
removal” on
page 4-62.
2-176 Service Manual
Media damage (using ADF)
Leading edge
Trailing edge
Step
Check
1
Properly load document into the ADF unit assembly and
ensure all guides are set correctly.
Yes
No
Go to step 2.
Problem solved.
Go to step 3.
Remove
obstructions.
Re-print the defective image.
Does the error continue?
2
Check for obstructions in the area of the media feed
path in the ADF.
Is the media feed path free from any obstructions?
3
Is the ADF left cover assembly properly and evenly
closed.
Go to step 4.
Open then
properly close
the ADF left
cover assembly.
4
Check the ADF/pick roll assembly for damage and
wear.
Go to step 5.
Replace the ADF
feed/pick roll
assembly.
Is the ADF feed/pick roll assembly free from damage
and wear?
5
Check the ADF separator roll.
Go to “ADF feed
/ pick roll
assembly
removal” on
page 4-61.
Go to step 6.
Is the separator roll free from damage and wear?
Replace the
separator roll.
Go to “ADF
separator roll
removal” on
page 4-62.
6
Check the ADF controller card assembly.
Replace the ADF controller card assembly.
Go to “ADF controller card removal” on page 4-67.
Perform a print test using the ADF.
Does the error continue?
Replace the
system card
assembly.
Problem solved.
Go to “System
card assembly
removal” on
page 4-50.
Diagnostic information
2-177
Network service check
Note: Before starting this service check, print out the network setup page. This page is found under Menu Reports - Network Settings. Consult the network administrator to verify that the physical and wireless network
settings displayed on the network settings page for the device are properly configured. If a wireless network is
used, verify that the printer is in range of the host computer or wireless access point, and there is no electronic
interference. Have the network administrator verify that the device is using the correct SSID, and wireless
security protocols. For more network troubleshooting information, consult the Dell Network Setup Guide.
Step
1
Questions / actions
If the device is physically connected to the
network, verify that the ethernet cable is
properly connected on both ends.
Yes
Go to step 3.
No
Go to step 2.
If the network is wireless,
got to step 3.
Is the cable properly connected?
2
Connect the ethernet cable.
Problem resolved
Go to step 3.
Go to step 5.
Go to step 4.
Problem resolved.
Go to step 5.
Did this fix the problem?
3
Check the printer’s online status under Printers
and Faxes on the host computer. Delete all
print jobs in the print queue.
Is the printer online and in a Ready state.
4
Change the printer status to online.
Did this fix the issue?
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?
Go to step 7.
Go to step 9.
Note: A printer should use a static IP
address on a network.
7
Are the first two segments if the IP address
169.254?
Go to step 8.
Go to step 9
8
POR the printer.
Problem resolved
Go to step 10.
Problem fixed.
Go to step 10.
Go to step 12.
Go to step 11.
Problem resolved.
Go to step 12.
Go to step 13.
Go to step15.
Is the problem resolved
9
Reset the address on the printer to match the
IP address on the driver.
Did this resolve the issue?
10
Have the network administrator verify that the
printer and PC’s IP address have identical
subnet addresses.
Are the subnet addresses the same?
11
Using the subnet address supplied by the
network administrator, assign a unique IP
address to the printer.
Note: The printer IP address should match
the IP address on the printer driver.
Did this fix the problem?
12
Is the device physically connected (ethernet
cable) to the network?
2-178 Service Manual
Step
13
Questions / actions
Try using a different ethernet cable.
Yes
No
Problem resolved
Go to step 14.
Replace the controller
board. Go to “System card
assembly removal” on
page 4-50.
Contact the network
administrator.
Did this remedy the situation?
14
Have the network administrator check the
network drop for activity.
Is the drop functioning properly?
15
Is the printer on the same wireless network as
the other devices?
Go to step 17.
Go to step 16.
16
Assign the correct wireless network to the
printer.
Problem resolved
Go to step 17.
Did this fix the problem?
17
Are the other devices on the wireless network
communicating properly?
Go to step 18.
Contact the network
administrator.
18
Verify that the wireless card is properly seated
on the controller board.
Go to step 20.
Go to step 19.
Problem resolved.
Go to step 20.
Is the wireless card seated correctly?
19
Properly reseat the wireless card.
Did this fix the problem?
20
Is the antenna damaged?
Go to step 22.
Go to step 21.
21
Replace the antenna.
Problem resolved
Go to step 22.
Go to step 24.
Go to step 23.
Problem resolved
Go to step 24.
Replace the wireless card.
Replace the system card
Did this fix the problem?
22
Verify that the antenna is properly connected
to the wireless card.
Is it connected correctly?
23
Properly connect the antenna.
Did this fix the problem?
24
Check pin 6 for +3.3V, and Pin 5 for +5V. on
connector <> of the controller board. Pins 1
and 4 are GND.
Are the voltages and GNDs correct?
Go to “System card
assembly removal” on
page 4-50.
Diagnostic information
2-179
2-180 Service Manual
3. Diagnostic aids
Understanding the printer control panel
1
2
1
4
GHI
7
2
ABC
5
JKL
8
3
DEF
6
MNO
9
PQRS
TUV
WXYZ
*
0
#
3
4
5
8
Item
7
6
Description
1
Display
2
Keypad
1
4
GHI
7
View scanning, copying, faxing, and printing options as well as status and error
messages.
Enter numbers or symbols on the display.
2
ABC
5
JKL
8
3
DEF
6
MNO
9
PQRS
TUV
WXYZ
*
0
#
3
Dial Pause
4
Back
• Press
to cause a two- or three-second dial pause in a fax number. In the
Fax To field, a Dial Pause is represented by a comma (,).
• From the home screen, press
to redial a fax number.
• The button functions only within the Fax menu or with fax functions. When
outside of the Fax menu, fax function, or home screen, pressing
causes
an error beep.
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 deleted, another press of
causes the cursor to move up one
line.
In the E-mail Destination List, press
to delete the character to the left of the
cursor. If the character is in a shortcut, then the shortcut is deleted.
Diagnostic aids
3-1
Item
Description
5
Home
6
Start
7
Indicator light
8
Stop
Press
to return to the home screen.
• Press
to initiate the current job indicated on the display.
• From the home screen, press
to start a copy job with the default settings.
• If pressed while a job is scanning, the button has no effect.
Indicates the printer status:
• Off—The power is off.
• Blinking green—The printer is warming up, processing data, or printing.
• Solid green—The printer is on, but idle.
• Blinking red—Operator intervention is needed.
Stops all printer activity
A list of options is offered once Stopped appears on the display.
Understanding the home screen
After the printer is turned on and a short warm-up period occurs, the display shows the following basic screen
which is referred to as the home screen. Use the home screen buttons to initiate an action such as copying,
faxing, or scanning; to open the menu screen; or to respond to messages.
1
2
8
Ready
Touch any button to begin.
7
Display item
1
Copy
2
3
E-mail
Menus
6
5
4
3
Description
Opens the Copy menus
Note: From the home screen, you can also access the Copy menus by pressing
a number on the keypad.
Opens the E-mail menu
Opens the menus
These menus are available only when the printer is in the Ready state.
3-2 Service Manual
Display item
4
FTP
5
Status message bar
6
Status/Supplies
7
Tips
8
Fax
Description
Opens the File Transfer Protocol (FTP) menus
Note: This function must be set up by your system support person. Once it is set
up, it appears as a display item.
• Shows the current printer status such as Ready or Busy.
• Shows printer conditions such as Toner Low.
• Shows intervention messages to give instructions on what you should do so
the printer can continue processing, such as Close door or Insert print
cartridge.
Appears on the display whenever the printer status includes a message requiring
intervention. Touch it to access the messages screen for more information on the
message, including how to clear it.
All menus have a Tips button. Tips is a context-sensitive Help feature within the
display touch screens.
Opens the Fax menus
Other buttons that may appear on the home screen:
Display item
Description
Release Held Faxes
If this button is shown, then there are held faxes with a scheduled hold time
previously set. To access the list of held faxes, touch this button.
Searches on any of the following items and returns search results:
Search Held Jobs
Held Jobs
Lock Device
Unlock Device
Cancel Jobs
• User names for held or confidential 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
Opens a screen containing all the held jobs
This button appears on the screen when the printer is unlocked and Device Lockout Personal Identification Number (PIN) has been set.
Touching this button opens a PIN entry screen. Entering the correct PIN locks the
printer control panel (touch screen and hard buttons).
This button appears on the screen when the printer is locked. The printer control
panel buttons and shortcuts cannot be used while it appears.
Touching this button opens a PIN entry screen. Entering the correct PIN unlocks
the printer control panel (touch screen and hard buttons).
Opens the Cancel Jobs screen. The Cancel Jobs screen shows three headings:
Print, Fax, and Network.
The following items are available under the Print, Fax, and Network headings:
• Print job
• Copy job
• Fax profile
• 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.
Diagnostic aids
3-3
Using the touch-screen buttons
Note: Depending on your options and administrative setup, your screens and buttons may vary from those
shown.
Sample touch screen
Button
Function
Home
Returns to the home screen
Scroll down
Opens a drop-down list
Left scroll decrease
Scrolls to another value in decreasing order
Right scroll increase
Scrolls to another value in increasing order
Left arrow
Scrolls left
3-4 Service Manual
Button
Function
Right arrow
Scrolls right
Submit
Saves a value as the new user default setting
Submit
Back
Navigates back to the previous screen
Other touch-screen buttons
Button
Function
Down arrow
Moves down to the next screen
Up arrow
Moves up to the next screen
Unselected radio button
This is an unselected radio button. 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.
Diagnostic aids
3-5
Button
Function
Cancel Jobs
Opens the Cancel Jobs screen. The Cancel Jobs
screen shows three headings: Print, Fax, and
Network.
The following items are available under the Print,
Fax, and Network headings:
• Print job
• Copy job
• Fax profile
• 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.
Touch this button when more changes need to be
made for a job or after clearing a paper jam.
Continue
Cancel
• Cancels an action or a selection
• Cancels out of a screen and returns to the
previous screen
Select
Selects a menu or menu item
This chapter explains the tests and procedures to identify printer failures and verify repairs have corrected the
problem.
3-6 Service Manual
Accessing service menus
There are different test menus that can be accessed during POR to identify problems with the printer.
Diagnostics Menu
1
4
GHI
7
2
ABC
5
JKL
8
3
DEF
6
MNO
9
PQRS
TUV
WXYZ
*
0
#
Configuration Menu
1
4
GHI
7
2
ABC
5
JKL
8
3
DEF
6
MNO
9
PQRS
TUV
WXYZ
*
0
#
1. Turn off the printer.
2. Press and hold the 3 and 6
buttons simultaneously for
about 10 seconds.
3. Turn on the printer.
4. Release the buttons after 10
seconds.
The Diagnostics Menu group consists of menus,
settings, and operations that are used to diagnose
various printer problems.
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 menu group are
used to configure a printer for operation.
Note: While the Diagnostics menu group is active,
all host interfaces are offline.
See “Diagnostics Menu” on page 3-8 for more
information.
See “Configuration menu (CONFIG MENU)” on
page 3-28 for more information.
Diagnostic aids
3-7
Diagnostics Menu
Entering Diagnostics Menu
1.
2.
3.
4.
Turn off the printer.
Press and hold 3 and 6 buttons simultaneously.
Turn on the printer.
Release the buttons after 10 seconds.
Available tests
The tests display on the operator panel in the order shown:
Note: Some menus are not available, depending on the configuration of the printer.
Diagnostics Menu tests
REGISTRATION
See “Registration (printer)” on page 3-11
Top Margin
Bottom Margin
Left Margin
Right Margin
Quick Test
See “Quick Test” on page 3-12
PRINT TESTS
Tray 1
See “Input source tests” on page 3-13
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
MP Feeder
Envelopes - MP Feeder (if installed)
Printing Print Quality Pages
See “Printing Quality Pages” on page 3-13
HARDWARE TESTS
Panel Test
See “Panel Test” on page 3-14
Button Test
See “Button Test” on page 3-14
DRAM Test
See “DRAM Test” on page 3-15
USB HS Test Mode
3-8 Service Manual
Diagnostics Menu tests (Continued)
DUPLEX TESTS (if installed)
Quick Test
See “Quick Test (duplex)” on page 3-16
Top Margin
See “Top Margin (duplex)” on page 3-17
Sensor Test
See “Sensor Test (duplex)” on page 3-17
Motor Test
See “Motor Test (duplex)” on page 3-17
Duplex Feed 1
See “Duplex Feed 1” on page 3-18
Duplex Feed 2
See “Duplex Feed 2” on page 3-18
INPUT TRAY TESTS
Feed Tests
See “Feed Tests (input tray)” on page 3-19
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
Envelope Feeder
MP Feeder
Sensor Tests
See “Sensor Test (input tray)” on page 3-19
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
Envelope Feeder
MP Feeder
OUTPUT BIN TESTS
See “OUTPUT BIN TESTS” on page 3-20
Feed Tests
Standard Bin
Sensor Tests
Standard Bin
BASE SENSOR TEST
See “BASE SENSOR TEST” on page 3-20
Toner Sensor
Input Sensor
Output Sensor
NarrowMedia
Front Door
DEVICE TESTS
Quick Disk Test
See “Quick Disk Test” on page 3-21
Disk Test/Clean
See “Disk Test/Clean” on page 3-21
Diagnostic aids
3-9
Diagnostics Menu tests (Continued)
PRINTER SETUP
Defaults
See “Defaults” on page 3-22
Printed Page Count
See “Printed Page Count” on page 3-22
Perm Page Count
See “Permanent Page Count” on page 3-22
Serial Number
See “Serial Number” on page 3-22
Envelope Enhance
See “Engine Settings 1 through 16” on page 3-22
Engine Settings 1 through 16
See “Engine Settings 1 through 16” on page 3-22
Model Name
See “Model Name” on page 3-22
Configuration ID
See “Configuration ID” on page 3-23
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 SETUP
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
See “Charge Roll” on page 3-25
Gap Adjust
See “Gap Adjust” on page 3-25
Auto Dark Adjust
See “Auto Dark Adjust” on page 3-25
REPORTS
Menu Settings Page
See “Menu Settings Page” on page 3-25
EVENT LOG
Display Log
See “Display Log” on page 3-25
Print Log
See “Print Log” on page 3-26
Clear Log
See “Clear Log” on page 3-26
SCANNER TESTS
Back Side Scan Uniformity
See “Back Side Scan Uniformity” on page 3-27
ASIC Test
See “Back Side Scan Uniformity” on page 3-27
Feed test
See “Feed Test” on page 3-27
Sensor Tests
See “Sensor Tests” on page 3-27
Touch Exit Diag Menu to exit the Diagnostics Menu, and Resetting the Printer displays. The printer
performs a POR, and the printer returns to ready mode.
Exit
Diag Menu
3-10 Service Manual
Registration (printer)
Print registration makes sure the printing is properly aligned on the page.
REGISTRATION
Top Margin
0
Bottom Margin
0
Left Margin
0
Right Margin
0
Quick Test
Submit
Back
The settings available are:
Description
Value
Direction of change
Top Margin
-25 to +25
A positive change moves the image down the
page and increases the top margin. A negative
change moves the image up and decreases the
top margin.
Each increment causes
approximately 4 pels shift (at
600 dpi).
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 positive change moves the image right, and a
negative change moves the image left.
Diagnostic aids
3-11
To set print registration:
1. Print the Quick Test page.
a. Touch REGISTRATION from the Diagnostics Menu.
b. Touch
to select Quick Test. You may need to scroll to the next page.
Retain this page to determine the changes you need to make to the margins settings. The diamonds in the
margins should touch the margins of the page.
2. To change the value of any of the margin settings:
• Touch
to the right of the appropriate margin setting. The panel displays the setting's name in the header
and
[setting's current value]
in a menu below the header row.
• Touch to decrease the value or to increase the value.
• Touch Submit to save the change, or Touch Back to cancel and return to the Diagnostics Menu.
• Touch Submit to save all changed values.
The device prints 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 count, installed memory, processor speed, serial
number, Engine ID, and system card ID.
To print the Quick Test page:
Note: Print the Quick Test Page on letter or A4 paper.
1. Touch REGISTRATION from the Diagnostics Menu.
2. Touch
to select Quick Test.
The message Quick Test Printing… appears on the display.
Once the Quick Test Page completes printing, the Registration screen displays again.
3. Touch Back to return to the Diagnostics Menu.
PRINT TESTS
Selections on the screen vary since only installed input sources are listed, followed by Printing Quality Test
Pages.
3-12 Service Manual
Input source tests
The purpose of the diagnostic Print Tests is to verify that the printer can print on media from each of the
installed input options. The contents of the Print Test Page varies depending on the media installed in the
selected input source.
Check each Test Page from each source to assist in print quality and paper feed problems.
To run the Print Test Page:
1. Select PRINT TESTS from the Diagnostics menu.
2. Select the media source to test:
Tray 1
Tray 2 (if installed)
Tray 3 (if installed)
Tray 4 (if installed)
Tray 5 (if installed)
MP Feeder (if installed)
Envelope Feeder (if installed)
3. Select Single or Continuous.
• If Single is selected, a single page is printed.
• If Continuous is selected, printing continues until Stop is pressed to cancel the test.
If a source is selected that contains envelopes, an envelope test pattern is printed. If Continuous is
selected, the test pattern is printed only on the first envelope.
Note: The 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 mixture of
graphics and text. Page two is gray with two one-inch black squares located on the bottom right. Page three is
a solid black page and page four is blank. If duplex is turned on, the pages are duplexed. The Print Quality Test
pages are printed in English and must always be printed on letter, legal, or A4 paper.
To run the Print Quality Test Pages, touch
beside Printing Quality Test Pages from PRINT TESTS. The
message Printing Quality Test Pages is displayed.
Note: The print quality test pages can also be printed from the Configuration menu (CONFIG MENU),
however, a cartridge must be installed with a machine class ID matching the machine class ID stored in
NVRAM. Additional diagnostic information may be printed on the pages when printing from DIAGNOSTICS.
Diagnostic aids
3-13
The following is included in the DIAGNOSTICS version of the print quality pages:
• Values from EP SETUP in DIAGNOSTICS, including:
Fuser temperature, warm-up time, transfer, print contrast, charge roll settings and gap adjust.
Contents of the EVENT LOG from DIAGNOSTICS.
•
• Configuration information, including printer serial number, controller code level, engine code level, operator
•
panel code level, font versions, and cartridge information.
Default values for the QUALITY MENU settings used to print the pages.
HARDWARE TESTS
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 verifies the operation of the buttons on the operator panel. When you select Button Test, a
diagram of the operator panel appears on the panel. When you press a button on the operator panel, the
corresponding touchscreen key is emphasized. Touch Back to cancel the test.
3-14 Service Manual
DRAM Test
The purpose of this test is to check the validity of DRAM memory, both standard and optional. The test writes
patterns of data to DRAM to verify that each bit in memory can be set and read correctly.
To run the DRAM Test:
1. Touch
to select DRAM Test from the menu.
The message DRAM Test Testing… displays. Then the message Resetting Printer appears, and
the power indicator light blinks red.
2. Turn the printer off and on. While the DRAM test executes, the power indicator blinks green.
The following type of message appears:
DRAM Test <###
P:######
F:####
• xxx represents the installed DRAM size.
• P:###### represents the number of times the memory test has passed and finished successfully. Initially
000000 displays with the maximum pass count being 999,999.
• F:##### represents the number of times the memory test has failed and finished with errors. Initially 0000
displays with the maximum fail count being 99,999. Initially only four digits appear, but additional digits
appear as needed.
Each time a test is completed, the number of pass and failures increments. If the test fails, the message
Failure displays for approximately three seconds, and the failure count increases by one.
The test continues until all standard and optional DRAM is tested. Once the 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 appears.
2. The printer automatically performs a Power On Reset (POR). While the CACHE test executes, the power
indicator blinks green.
The following type of message appears:
CACHE Test <###
P:######
F:####
• P:###### represents the number of times the cache has passed and finished successfully. Initially 000000
displays with the maximum pass count being 999,999.
• F:##### represents the number of times the cache has failed and finished with errors. Initially 0000 displays
with the maximum fail count being 99,999. Initially only four digits appear, but additional digits appear as
needed.
Each time a test is completed, the number of passes and failures increments. If the test fails, the message
Failure displays for approximately three seconds, and the failure count increases by one.
The test continues until all of the printer processor’s cache has been tested. Once the 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 this test before completion, turn the MFP off.
Diagnostic aids
3-15
USB HS Test Mode
1. Select USB HS Test Mode from HARDWARE TESTS.
2. Press
until the
appears next to the Port to be tested, and then press
3. Select the desired Test, and then press
.
Port
Test
Appears on the display
Port 0
Test J
Test K
Test SEO NAK
Test Packet
Test Force Enabled
USB High Speed
Certification Testing...
Port 1
Test J
Test K
Test SEO NAK
Test Packet
Test Force Enabled
USB High Speed
Certification Testing...
Port 2
Test J
Test K
Test SEO NAK
Test Packet
Test Force Enabled
USB High Speed
Certification Testing...
Port 3
Test J
Test K
Test SEO NAK
Test Packet
Test Force Enabled
USB High Speed
Certification Testing...
.
To stop testing before completion, turn the printer off.
DUPLEX TESTS
Quick Test (duplex)
This test prints a duplex version of the Quick Test that can be used to verify that the correct placement of the
top margin on the back side of a duplex page. You can run one duplexed page (Single), or continue printing
duplexed pages (Continuous) until Stop
is pressed. For information about changing the margin, see
“Top Margin (duplex)” on page 3-17.
Note: Before you set the duplex top margin, be sure to set the registration. See “Registration (printer)” on
page 3-11.
The paper you choose to print the page on should be either Letter or A4.
To run the Quick Test (duplex):
1. Touch
to select Quick Test from DUPLEX TESTS.
2. Touch
to select Single or Continuous.
• The single Duplex Quick test cannot be canceled.
• 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 continuous test continues
until you press Stop
.
3-16 Service Manual
Top Margin (duplex)
This setting controls the offset between the first scan line on the front of the duplex page and the first scan line
on the back of the page. Therefore, be sure to set the top margin in REGISTRATION before setting the duplex
top margin. See “Registration (printer)” on page 3-11.
To set the Top Margin (duplex):
1. Print the Quick Test (duplex):
a. Touch
to select Quick Test from DUPLEX TESTS.
b. Select Single.
c. Hold the page to the light to see the whether the top margin of the backside aligns with the
top margin of the front side.
2. Select Top Margin from DUPLEX TESTS.
3. Use the arrows to increase or decrease the current setting displayed on the touchscreen to select the
margin setting:
[setting's current value] .
• Each increment shifts the duplex top margin by 1/100 of an inch.
• The Top Margin (duplex) range is -25 to +25, and the default value is 0.
• An increase moves the top margin down and widens the top margin. A decrease moves the top margin
upward and narrows the top margin.
4. Touch Submit.
5. Print the Quick Test (duplex) again to verify the adjustment. Repeat if necessary.
Sensor Test (duplex)
This test is used to determine 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 (closed) displays, and
when the sensor/switch is open, OP (open) displays.
• Duplex input sensor
• Duplex exit sensor
3. Press Stop
to exit the test.
Motor Test (duplex)
This test lets you test the duplex option paper feed drive system, and verify that the power and velocity values
are acceptable. The duplex runs the DC motor at high speed and low speed, taking an average of the power
(PWM) required for each speed and calculating the KE value.
To run the Motor Test (duplex):
1. Select Motor Test from DUPLEX TESTS.
The power indicator light blinks, and the message Motor Test Testing displays.
2. When the motor stops, the results are displayed. Listed below is an example of such results:
Duplex Motor Test Test Passed
Avg. PWM of High-Speed Test: 1d
Avg. PWM of Low-Speed Test: Oe
Max. PWM of Low-Speed Test: 00
Min. PWM of Low-Speed Test: 0b
Motor KE Value: 2d
Motor Test Results: 00
Diagnostic aids
3-17
3. Touch Back or press Stop
to exit the test.
Duplex Feed 1
This test feeds a blank sheet of paper to the duplex paper stop position 1. This test can be run using any of the
supported paper sizes.
To run the Duplex Feed 1 Test:
1. Touch
to select Duplex Feed 1 from DUPLEX TESTS.
The power indicator blinks while the paper is feeding, and the message Duplex Feed 1 Feeding…
displays.
The message Duplex Feed 1 Clear Paper displays when the paper reaches paper stop position 1,
and the power indicator 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 feeding, and the message Duplex Feed 2 Feeding…
displays.
The message Duplex Feed 2 Clear Paper displays when the paper reaches the duplex paper stop
position 2, and the power indicator turns on solid.
2. Remove the media from the duplex unit, and clear the message on the operator panel by touching Back or
pressing Stop
.
3-18 Service Manual
INPUT TRAY TESTS
Feed Tests (input tray)
This test lets the servicer observe the paper path as media is feeding through the printer. A blank sheet of
paper feeds through the printer as the laser turns off during this test. The only way to observe the paper path is
to open the lower front door that is used to access the envelope or multipurpose feeder. The paper is placed in
the output bin.
To run the Input Tray Feed Tests:
1. Touch
to select Feed Tests from INPUT TRAY TESTS.
2. Touch
to select the input source from the sources displayed on the Feed Tests menu. All installed
sources are listed.
3. Touch
to select either Single or Continuous.
• Single—feeds one sheet of media from the selected source.
• Continuous—media continues feeding from the selected source until Stop
is pressed.
Sensor Test (input tray)
This test is used to determine if the input tray sensors are working correctly. To run the Input Tray Sensor Test:
1. Touch
to select the Sensor Test from INPUT TRAY TESTS.
2. Touch
to select the input source from the sources displayed on the Sensor Test menu. All installed
sources are listed.
3. Select the sensor to test. Various sources have different combinations of sensors. See the table below:
Tray sensor support by source
Source
Empty
(Input tray empty
sensor)
Low
(Input tray paper low
sensor)
passThru
(Input tray pass thru
sensor)
Tray 1
X
X
Tray 2
X
X
X
Tray 3
X
X
X
Tray 4
X
X
X
Tray 5
X
X
X
Multipurpose tray
X
Envelope feeder
X
[sensor selected]=Open displays.
• Empty—Input tray empty sensor
• Low—Input tray paper low sensor
• passThru—Input tray pass thru sensor
4. Once this message displays, the servicer can manually actuate each sensor. The tray empty sensor can be
actuated by hand, however a sheet of paper can be used to cover the pass thru sensor. When the sensor
is closed, Closed displays; when the sensor is open, Open displays.
5. Press Stop
to exit the test.
Diagnostic aids
3-19
OUTPUT BIN TESTS
Feed Tests (output bins)
Use these tests to verify that media can be fed to the standard output bin. No information is printed on the
media fed to the output bin, because the printhead is not engaged during this test. These tests can use any
media size or envelope supported by the printer.
To run the Feed Tests for the output bins:
1. Touch
to select Feed Tests from the OUTPUT BIN TESTS.
2. Touch
to select the output bin you want the paper to exit into.
3. Touch
to select either Single or Continuous.
• Single—feeds one sheet of media from the selected source.
• Continuous—media continues feeding from the selected source until Stop
is pressed.
Touch Back to return to OUTPUT BIN TESTS.
Sensor Test (standard output bin)
This 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
to exit the test.
BASE SENSOR TEST
This test is used to determine if the sensors located inside the printer are working correctly.
To run the Base Sensor Test:
1. Select BASE SENSOR TEST from the DIAGNOSTICS menu.
The following sensors are listed:
• Toner Level—Toner level sensor (remove the cartridge and replace to actuate the sensor)
•
•
•
•
Input—Input sensor
Output—Output (exit) sensor
NarrowMedia—Output (exit) sensor
Front Door—Front door sensor
2. Manually actuate the sensors to verify that each sensor switches from Open to Closed.
3. Press Stop
to exit the test.
3-20 Service Manual
DEVICE TESTS
Quick Disk Test
This test performs a non-destructive read/write on one block per track on the disk. The test reads one block on
each track, saves the data, and proceeds to write and read four test patterns to the bytes in the block. If the
block is good, the saved data is written back to the disk.
To run the Quick Disk Test:
1. Touch
to select Quick Disk Test from DEVICE TESTS.
The power indicator blinks while the test is in progress, and quick Disk Test Testing… displays.
• Quick Disk Test/Test Passed message displays if the test passes, and the power indicator turns on
solid.
• Quick Disk Test/Test Failed message displays if the test failed, and the power indicator turns on
solid.
2. 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 1½ 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 all contents on the disk
will be lost.
2. Touch Yes to continue and No to exit.
If Yes is selected, the following screen displays and updates periodically, indicating the percentage of test
completed.
Formatting Disk
0%
1/1
DO NOT POWER OFF
The power indicator blinks during the test.
Note: The test can NOT be canceled.
3. Once the test is complete, the power indicator turns on solid, and either the message Disk Test/Clean
Test Passed or Disk Test/Clean Failed appears. If the message indicates failure, the disk is
unusable.
Diagnostic aids
3-21
PRINTER SETUP
PRINTER SETUP
Defaults
US
Printed Page Count
127
Permanent Page Count
127
Serial Number
xxxxxxx
Engine Setting 1
0
Engine Setting 2
0
Submit
Back
The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to
display these additional menus.
Note: If you make changes, touch Submit to make the change effective.
Defaults
US/Non-US defaults changes whether the printer uses the US factory defaults or the non-US factory defaults.
The settings affected include paper size, envelope size, PCL symbol set, code pages, and units of measure.
Warning: Changing this setting resets the printer to factory defaults, and 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.
Engine Settings 1 through 16
Warning: Do not change these settings unless requested to do so by your next level of support.
Model Name
The model name can only be viewed and cannot be changed.
3-22 Service Manual
Configuration ID
The two configuration IDs are used to communicate information about certain areas of the printer that cannot
be determined using hardware sensors. The configuration IDs are originally set at the factory when the printer
is manufactured, however, the servicer may need to reset Configuration ID 1 or Configuration ID 2 whenever
you replace the system board. The IDs consist of eight hexadecimal characters, including 0 through 9 and A
through F.
Note: When the printer detects a Configuration ID that is not defined or invalid, the following occurs:
• The default standard model Configuration ID is used instead.
• Configuration ID is the only function available in DIAGNOSTICS.
• Unless the menu is in DIAGNOSTICS, Check Config ID displays.
To set the configuration ID:
1. Touch
to select PRINTER SETUP from the Diagnostics Menu.
2. Touch
to select Configuration 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 icon.
• To exit without changing the numbers, touch Back.
Note: Be sure to touch Submit, or the number will not be changed.
Submitting Selection displays, followed by the value for Configuration ID 1.
Note: If Invalid ID appears, the entry is discarded, and the previous Configuration ID 1 is displayed on
the screen.
If the process is successful, Submitting Selection appears on the display, followed by the current
value for Configuration ID 2.
4. Restart the printer.
Edge to Edge
When this setting is On, the text and graphics are shifted to the physical edges of the paper for all margins.
When the setting is Off, the normal margins are restored.
Enable Edge to Edge Copy
The settings are ON and OFF.
Diagnostic aids
3-23
EP SETUP
EP SETUP
EP Defaults
Fuser Temp
Fuser Page Count
Normal
127
Warm Up Time
Transfer
Medium
Print Contrast
Medium
Submit
Back
The triangles pointing up or down indicate whether there are additional menus. Touch the up or down arrows to
display these additional menus.
Note: If you make changes, touch Submit to make the change effective.
EP Defaults
This setting is used to restore each printer setting listed in EP SETUP to its factory default value. Sometimes
this is used to help correct print quality problems.
To restore EP Defaults:
1. Touch
to select EP Defaults from EP SETUP.
2. Touch
to select Restore to reset the values to the factory settings, and touch
Restore to exit without changing the settings.
to select Do Not
Touch Back to exit without changing the settings.
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 to return to Diagnostics Menu.
Warm Up Time
You can change the amount of time the printer warms up before allowing pages to print by changing this
setting from 0 to 5. The factory sets the warm up at 0 or no warm up time. This time period lets the backup roll
heat up and helps reduce curl in some environments.
Touch Back to return to Diagnostics Menu.
3-24 Service Manual
Transfer
The transfer can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Print Contrast
The print contrast setting controls the developer voltage offset.
The print contrast can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Charge Roll
The charge roll can be adjusted to Low, Medium, or High. The default setting is Medium.
Touch Back to return to Diagnostics Menu.
Gap Adjust
The setting adjusts the minimum gap between sheets. Increasing this value may reduce curl of some printed
media and eliminate some output bin stacking problems. However, increasing this value also results in slower
overall performance, measured in pages per minute. The range of values is 0 to 255, and the default value is 0.
Touch Back to return to Diagnostics Menu.
Auto Dark Adjust
The settings are Enable and Disable.
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 provides a history of printer errors. It contains the 12 most recent errors that have occurred on
the printer. The most recent error displays in position 1, and the oldest error displays in position 12 (if 12 errors
have occurred). If an error occurs after the log is full, the oldest error is discarded. Identical errors in
consecutive positions in the log are entered, so there may be repetitions. All 2xx and 9xx error messages are
stored in the event log.
To view the event log:
1. Touch
to select Display Log from EVENT LOG.
Up to three error codes display at a time. Touch
to display additional information, if available.
2. Touch Back to return to the EVENT LOG menu.
Diagnostic aids
3-25
Print Log
Additional diagnostic information is available when you print the event log from Diagnostics Menu rather than
Configuration Menu.
The Event Log printed from Diagnostics Menu includes:
•
•
•
•
Detailed printer information, including code versions
Time and date stamps
Page counts for most errors
Additional debug information in some cases
'HOOGQVQ;;;;;;;;;
The printed event log can be faxed to Dell or your next level of support for verification or diagnosis.
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 displays on the screen.
3-26 Service Manual
SCANNER TESTS
Back Side Scan Uniformity
This procedure should be run after the ADF has been replaced. Before proceeding, make sure that the
scanner glass and backing material are clean.
ASIC Test
A pattern appears and ASIC Test Passed displays. If xxxxxx displays, the test was unsuccessful.
Press Stop
to return to the SCANNER TESTS menu.
Feed Test
To run the Scanner Feed test:
1. Touch
to select Feed Test from the SCANNER TESTS menu.
2. The panel displays the setting's current value [setting's current value]
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.
. Use the arrows to select from
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 interlock)
Sensor (ADF media exit sensor)
Sensor (ADF lower door interlock)
Sensor (ADF 1st scan)
Sensor (ADF 2nd scan)
Sensor (FB length 1)
Sensor (FB length 2)
Sensor (FB length 3)
Sensor (ADF long media)
Sensor (ADF Width 1)
Sensor (ADF Width 2)
Sensor (ADF Width 3)
Sensor (ADF Width 4)
Diagnostic aids
3-27
Configuration menu (CONFIG MENU)
Entering Configuration Menu
1.
2.
3.
4.
Turn off the printer.
Press and hold 2 and 6 buttons simultaneously.
Turn on the printer.
Release the buttons after 10 seconds.
Available menus
Note: Some menus are not available, depending on the configuration of the printer.
Maintenance Counter Value
See “Maintenance Counter Value” on page 3-29
Reset Maintenance Counter
See “Reset Maintenance Counter” on page 3-29
USB Scan to Local
See “USB Scan to Local” on page 3-30
Print Quality Pages
See “USB Scan to Local” on page 3-30
Reports
See “Reports” on page 3-31
• Menu Settings Page
• Event Log
SIZE SENSING
See “SIZE SENSING” on page 3-31
Panel Menus
See “Panel Menus” on page 3-32
PPDS Emulation
See “PPDS Emulation” on page 3-32
Factory Defaults
See “Factory Defaults” on page 3-33
Energy Conserve
See “Energy Conserve” on 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
FB Edge Erase
See “FB Edge Erase” on page 3-35
Scanner Manual Registration
See “Scanner Manual Registration” on page 3-35
Disable Scanner
See “Disable Scanner” on page 3-36.
Paper Prompts
See “Disable Scanner” on page 3-36
Envelope Prompts
See “Envelope Prompts” on page 3-36
Action for Prompts
See “Action for Prompts” on page 3-37
Jobs On Disk
See “Action for Prompts” on page 3-37
Disk Encryption
See “Disk Encryption” on page 3-38
Wipe Disk
See “Wipe Disk” on page 3-39
Font Sharpening
See “Font Sharpening” on page 3-39
Require Standby
See “Require Standby” on page 3-39
LES App[lications
See “LES Applications” on page 3-40
Key Repeat Initial Delay
See “Key Repeat Initial Delay” on page 3-40
Key Repeat Rate
See “Key Repeat Rate” on page 3-40
Wiper Message
See “Wiper Message” on page 3-40
Clear Custom Status
See “Clear Custom Status” on page 3-40
3-28 Service Manual
Touch Exit Config Menu to exit the Configuration Menu, and Resetting the Printer displays. The
printer performs a POR, and the printer returns to the ready mode.
Exit
Config Menu
Maintenance Counter Value
The current value for the maintenance page counter is displayed. This counter tracks printer usage. A print job
containing a single page increments the counter by one and a duplex page by two. At 300,000, the customer is
reminded that the printer requires scheduled maintenance. This counter is reset by the servicer after an 80
Scheduled Maintenance message displays and a maintenance kit is installed.
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 maintenance page count to zero:
1. Touch
to select Reset Maintenance Counter from the Configuration Menu.
2. Touch Yes to reset the counter, or touch No to exit without resetting the counter.
Reset Maintenance Counter
Yes
No
When the reset operation is complete, the menu returns to the main Configuration Menu.
Diagnostic aids
3-29
USB Scan to Local
To change the USB Scan to Local setting:
1. Touch
to select USB Scan to Local from the Configuration Menu.
2. The panel displays the setting's name in the header and
[setting's current value]
below the header
row. 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.
Print Quality Pages
The print quality test pages can be printed from either the Diagnostics Menu or Configuration Menu (CONFIG
MENU). When printed from the Diagnostics Menu, additional information is included, and the print cartridge
lockout is bypassed. See “USB Scan to Local” on page 3-30. Additional configuration information may be
included on the print quality pages which is not included on the print menu 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 Margin Settings
Minimum Stroke Width
The print quality pages consist of four pages. Page one contains a mixture of graphics and text. Page two is
gray with two one-inch black squares located on the bottom right. Page three is solid black page and page four
is blank. If duplex is turned on, the pages are duplexed. The Print Quality Test pages are printed in English and
must always be printed on letter, legal, or A4 paper.
3-30 Service Manual
Reports
Menu Settings Page
To print the Menu Settings Page, touch
to select Menu Settings Page from Reports. The message
Printing Menu Settings Page is displayed.
The following settings are printed:
Maintenance Counter Value
USB Scan to Local
Print Quality Pages
Reports
SIZE SENSING
Panel Menu
PPDS Emulation
Factory Defaults
Energy Conserve
Min Copy Memory
NumPad Job Assist
Fax Storage Location
ADF Edge Erase
FB Edge Erase
Scanner Manual Registration
Disable Scanner
Paper Prompts
Envelope Prompts
Disk Encryption
Wipe Disk
Font Sharpening
Required Standby
LES Applications
Key Repeat Initial Delay
Key Repeat Rate
Wiper Message
Clear Custom Status
Touch Back to return to the Configuration Menu.
Event Log
The event log provides a history of printer errors. The event log can only be printed in CONFIG MENU.
Additional options are available in DIAGNOSTICS. See “EVENT LOG” on page 3-25.
To print the event log:
1. Touch
to select Event Log from Configuration Menu.
2. Touch
to print the log. Printing EVENT LOG.. displays on the touchscreen.
3. Touch Back to return to EVENT LOG.
Note: An event log printed from the CONFIG MENU will not contain debug information or secondary codes for
900 service errors. However, the event log printed from DIAGNOSTICS mode does include this information.
SIZE SENSING
This setting controls whether the printer automatically registers the size of paper installed in an input source
with size sensing.
Paper source
Tray 1 (integrated)
Size sensing
X
Multipurpose feeder
250-sheet drawer
X
550-sheet drawer
X
2000-sheet drawer
X
250-sheet duplex
550-sheet duplex
Envelope feeder
Diagnostic aids
3-31
When the setting is Auto, every input option equipped with size sensing hardware automatically registers what
size media it contains. When the setting is Off, the media size detected by hardware is ignored. The media size
can be set by the operator panel or the data stream.
To change the size sensing setting:
1. Touch
to select SIZE SENSING from the Configuration Menu.
2. The panel displays the setting's name in the header and
[setting's current value]
row. Touch
or
to change the setting. The selections are Auto and Off.
3. Touch Submit to save your change.
below the header
Touch Back to exit without changing the value.
Panel Menus
To change the Panel Menus setting:
1. Touch
to select Panel Menus from the Configuration Menu.
2. The panel displays the setting's name in the header and
[setting's current value]
below the header
row. Touch
or
to change the setting. The selections are 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 changed:
• SmartSwitch settings for each port are turned off.
• The printer language is changed to PPDS Emulation.
Users can still switch languages on the operator panel and through the PJL data stream.
To change the PPDS Emulation setting:
1. Touch
to select PPDS Emulation from the Configuration Menu.
2. The panel displays the setting's name in the header and
[setting's current value]
below the header
row. Touch
or
to change the setting. The selections are On and Off. The default is Off.
3. Touch Submit to save your change.
Touch Back to exit without changing the value.
3-32 Service Manual
Factory Defaults
This setting enables a user to restore all the printer settings to the original factory settings. Selections are
Restore Base, Restore STD NET, or Restore LES. Restore LES enables you to remove all LXK
Embedded Solutions applications (LES).
Network does not appear unless you have a network printer. The following settings are not changed:
• Display language
• Settings in the NETWORK/PORTS MENU group.
To reset factory defaults:
1. Touch
2. Touch
to select Factory Defaults from the Configuration Menu.
to select either Restore Base, Restore STD NET, or Restore LES.
Note: There is no confirmation, and selecting one of these settings immediately takes effect. The MFP
restarts and returns to Ready state.
Restoring Factory Defaults and then Resetting the Device are displayed.
Factory Defaults
Restore Base
Restore STD Net
Restore LES
Back
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 Configuration Menu.
2. The panel displays the setting's name in the header and
[setting's current value]
below the header
row. Touch
or
to change the setting. The selections are On and Off. The default is On.
3. Touch Submit to save your change.
Touch Back to exit without changing the value.
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3-33
Min Copy Memory
1. Touch
to select Min Copy Memory from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
below the header
row.
2. Touch
or
to change the setting.
For example, the values may be 25 MB, 35 MB, 50 MB, and 100 MB. The default is 25 MB. Values will only
be displayed if the amount of installed DRAM is at least twice the amount of the value, that is, at least
200 MB of installed DRAM is required to display the 100 MB selection.
3. Touch Submit to save your change.
Touch Back to exit without changing the value.
NumPad Job Assist
1. Touch
to select NumPad Job Assist from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
row.
2. Touch
or
to change the setting.
The settings are On and OFF.
3. Touch Submit to save your change.
below the header
Touch Back to exit without changing the value.
Format Fax Storage
This setting enables you to format the non-volatile 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 Location from the Configuration Menu.
1. Touch
or
to change the setting.
The settings are Disk and NAND.
2. Touch Submit to save your change.
Touch Back to exit without changing the value.
ADF Edge Erase
The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the
scanned image that will be erased. For copies, the printed page will have a 2 mm no-print border. The larger of
the 2 mm no-print border and the Edge Erase setting will be used in this situation.
To change this setting:
1. Touch
to select ADF Edge Erase from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
row.
2. Touch
to increase the value or
to decrease the value.
The values are 0 through 6. The default is 3.
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below the header
3. Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
FB Edge Erase
The ADF Edge Erase and FB Edge Erase settings specify, in millimeters, the size of a border around the
scanned image that will be erased. For copies, the printed page will have a 2 mm no-print border. The larger of
the 2 mm no-print border and the Edge Erase setting will be used in this situation.
To change this setting:
1. Touch
to select FB Edge Erase from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
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.
below the header
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 displays the following headers:
• Print Quick Test
• Copy Quick Test
• Flatbed
2. Touch Print Quick Test to print a registration page.
3. Choose the section of the scanner to align.
To align the scanner glass (flatbed):
a. Place the Quick Test page facedown on the scanner glass.
b. Touch Copy Quick Test.
The scanner prints a copy of the Quick Test page.
c. Touch Flatbed.
Diagnostic aids
3-35
d. Use the copy of the Quick Test page to adjust the Left Margin and Top Margin settings.
e. Touch Submit.
f. Touch Copy Quick Test and compare the new copy to the original. Repeat the flatbed
alignment steps until the position on the page of the Quick Test copy closely matches the
original.
•
•
To align the ADF:
a. Do one of the following:
To align the ADF front: place the Quick Test page face up, short edge first into the ADF.
To align the ADF back: place the Quick Test page facedown, short edge first into the ADF.
b. Touch Copy Quick Test.
The scanner prints a copy of the Quick Test page.
c. Touch ADF Front or ADF Back.
d. Use the copy of the Quick Test page to adjust the Horizontal Adjust and Top Margin settings.
e. Touch Submit.
f. Touch Copy Quick Test and compare the new copy to the original.
Repeat the ADF alignment steps until the position on the page of the Quick Test copy closely matches the
original.
Touch Back to cancel and return to the Configuration Menu
Disable Scanner
To change 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 to fill.
1. Touch
to select Paper Prompts from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
row.
2. Touch
or
to change the value.
The values are Auto (default), MP Feeder, and Manual Paper.
3. Touch Submit to save the change.
below the header
Touch Back to exit without changing the value.
Envelope Prompts
This setting controls the tray the user is directed to refill when a specific envelope size is out. The selections
are Auto (default), MP Feeder, and Manual Envelope.
1. Touch
to select Envelope Prompts from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
row.
2. Touch
or
to change the value.
The values are Auto (default), MP Feeder, and Manual Envelope.
3. Touch Submit to save the change.
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below the header
Touch Back to exit without changing the value.
Action for Prompts
1. Touch
to select Action for Prompts from the Configuration Menu.
The panel displays the setting's name in the header and
[setting's current value]
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.
below the header
Touch Back to exit without changing the value.
Diagnostic aids
3-37
Jobs On Disk
If the hard disk is installed, Jobs On Disk allows the user to delete buffered jobs saved on the disk. The values
are Delete and Do Not Delete.
To delete jobs saved on the disk:
1. Touch
2. Touch
3. Touch
to select Jobs On Disk from the Configuration Menu.
to select Delete to delete buffered jobs saved on the disk.
to select Do Not Delete cancel and return to the Configuration Menu.
Disk Encryption
If a hard disk is installed, Disk Encryption selects whether the data on the disk is encrypted or not. The values
are Disable and Enable. This setting determines if the printer encrypts the information that it writes to the hard
disk.
Warning: If the value is changed from Enable to Disable or from Disable to Enable, then the printer
completely formats the hard disk. All information on the disk will be unrecoverable.
To change this setting:
1. Touch
to select Disk Encryption from the Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change
the setting. If no advanced password exists, you can establish one by using the keyboard that appears on
the LCD.
2. Touch
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 from the device.
3. Contents will be lost. Continue? appears on the touchscreen. Touch No to cancel or Yes to
proceed. If you select Yes, the printer performs the selected action on the hard disk. The following graphic
appears when the encryption process is selected:
The panel provides many progress indicators during the two-stage process.
• 1/2 indicates that the process is currently in the first stage.
• 0% indicates the progress of the current stage of the process.
• The progress bar indicates the overall completion of the entire process by filling in throughout each separate
stage.
When the first stage of either process completes, the printer displays either of the following graphics
depending on the process selected and then begins the second stage of the process:
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The entire process is complete when the progress bar appears completely shaded and the percentage
indicator shows 100%. After completion, the panel returns to Disk Encryption.
Wipe Disk
This setting provides you with a tool for erasing the contents of a disk.
Warning: Wipe Disk removes a disk's data in such a way that it cannot be recovered.
To change this setting:
1. Touch
to select Wipe Disk from Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change
the setting. If no advanced password exists, you can establish one by using the keyboard that appears on
the LCD.
2. Touch
to select Wipe disk now.
Contents will be lost. Continue? appears on the touchscreen.
3. Touch Back to return to Configuration Menu.
4. Touch Yes to continue, or touch No to exit.
Font Sharpening
This setting allows a user to set a text point size below which the high frequency screens are used when
printing 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 change.
Touch Back to cancel and return to the Configuration Menu.
This function is not supported when the device generates output at 600 dpi resolution.
Require Standby
This setting determines if the Standby Mode is On or Off. The default is On.
If Standby Mode is On, the printer begins functioning in Standby Mode when it remains idle for an amount of
time. The Standby Mode enables the printer:
• To consume less energy than when operating in normal mode but not as little as when operating in Power
Saver
• To return to the Ready state more quickly than when operating in Power Saver
To change this setting:
1. Touch
to select Require Standby from the Configuration Menu.
2. Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
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3-39
LES Applications
This disables all installed LXK Embedded Solution applications. The default is Enabled.
To change this setting:
1. Touch
to select LES Applications from the Configuration Menu.
Note: If an advanced password has been established, you must enter this password in order to change
the setting. If no advanced password exists, you can establish one by using the keyboard that appears on
the LCD.
2. Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Key Repeat Initial Delay
When a key is touched repeatedly, this is the delay before the key begins repeating. The delay ranges from
0.25 seconds to 5 seconds. The default is 1 second. Values are given in increments of 0.25 seconds.
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 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 return to the Configuration Menu.
Wiper Message
To change this setting:
1. Touch
to select Wiper Message from the Configuration Menu.
2. Touch
or
to change the value. The values are On (default) and Off.
3. Touch Submit to save the change.
Touch Back to cancel and return to the Configuration Menu.
Clear Custom Status
No values exist for this operation. Pressing
Touch
initiates this operation.
to select Clear Custom Status from the Configuration Menu.
Note: Executing this operation erases any strings that have been defined by the user for the default or
alternate custom messages.
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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
Diagnostic aids
3-41
Printer configurations
Note: Printer configuration may vary depending on your printer model.
Basic models
1
2
7
3
2
4
5
6
1
Automatic Document Feeder (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
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 www.dell.com.
3-42 Service Manual
Printer theory
Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors
PC drum
Sensor (input)
Standard bin full actuator
and sensor (standard bin full)
Diverter
PC cartridge
Sensor (fuser output)
Sensor (narrow media)
Sensor (option
pass through)
Sensor
(duplex input)
Pick arm
assembly
Diagnostic aids
3-43
Model X658 paper path rolls and sensors
PC drum
Sensor (input)
Standard bin full actuator
and sensor (standard bin full)
Diverter
PC cartridge
Sensor (fuser output)
Sensor (narrow media)
Sensor (option
pass through)
Sensor
(duplex input)
Pick arm
assembly
Functions of main components
•
•
•
•
•
•
•
•
Media tray assembly
Pic arm assembly (feed)
MPF
Xerographics
Transfer
Fuser
Drive
Electrical components and rolls
Media tray assembly
It is necessary to adjust the media tray rear guide and media tray side guide of the media tray assembly to
match the media size.
3-44 Service Manual
Rear media guide
The rear media tray guide assembly can be adjusted to different media sizes by moving it to the front or rear.
The rear guide should come into contact with the media and hold it in position.
Side guide
The media tray assembly is designed so it can adapt to the media width in the media feed direction by moving
the side guide to the left or right.
Wear strips
The wear strips are designed to provide a fixed resistance to ensure that a single piece of paper is properly fed
out of the media tray. There are several types of wear strips available for custom or hard to feed media.
Diagnostic aids
3-45
Media tray assembly
Wear strips
Side guides
End guides
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Detection of media size
The media size set for the media tray assembly is transmitted to the switch (media size) by moving these
guides. The media size is detected by the on/off information of these switches.
Pick arm assembly
Sensor (media empty)
Media out actuator
Sensor (media low)
Pick roll assemblies
Since all media trays are functionally equivalent in terms of the switch (media size), sensor (media empty),
sensor (media low), only the components of one tray are described here.
The pick arm assembly is a mechanical unit supplying media from the media tray assembly to the printer. The
driving force, from the pick arm drive motor on the pick arm assembly, is transmitted to the two pick rolls to
feed media.
When 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, it picks very
gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore
no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque
from the motor produces a movement about the pivot of the arm. 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
paper is physically held and not allowed to feed, then the motor stalls. Slippage between the roll and the paper
is theoretically impossible. When the motor is energized, the pick rolls are driven down into the stack,
increasing the normal force and drive force until the bending strength of the paper is overcome and the paper
bends and moves up the wear strip.
Switch (media size)
This switch (media size) sets the size of media supplied from each media tray assembly. A signal indicating the
media size is transmitted as a voltage to the printer system card assembly.
Sensor (media empty)
If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area
of the sensor (media empty). The sensor light is transmitted. When the sensing area is blocked (media is
present), the signal is off.
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3-47
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.
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 pick solenoid
Sensor (MPF media empty)
MPF pick roll assembly
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.
3-48 Service Manual
Sensor (MPF media empty)
The sensor (MPF media out) detects whether media is present on the MPF.
Supported paper sizes, types, and weights
The following tables provide information on standard and optional paper sources and the types of paper they
support.
Note: For an unlisted paper size, select the closest larger listed size
Paper sizes supported by the printer
250-or 550-sheet
trays (standard
or optional
Paper size
Dimensions
A4
210 x 297 mm
(8.3 x 11.7 in.)
x
A5
148 x 210 mm
(5.8 x8.3in.)
x
A61,2
105 x 148 mm
(4.1 x 5.8 in.)
J15 B5
182 x 257 mm
(7.2 x 10.1 in.)
x
Letter
216 x 279 mm
(8.5 x 11 in.)
x
Legal
216 x 356 mm
(8.5 x14 in.)
x
Executive
184 x 267 mm
(7.3 x 10.5 in.)
Oficio1
Optional
2000-sheet
tray
x
Multipurpose
feeder
Duplex unit
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
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
(2.8 x 5 in.) up
to
216 x 356 mm
(8.5 x 14 in.)
148 x 182 mm
(5.8 x 7.7 in.) up
to
216 x 356 mm
(8.5 x 14 in.)
x
x
x
7 3/4 Envelopes
(Monarch)
98 x 191 mm
(3.9 x 7.5 in.)
x
9 Envelope
98 x 225 mm
(3.9 x 8.9 in.)
x
10 Envelope
105 x 241 mm
(4.1 x 9.5 in.)
x
x
Diagnostic aids
3-49
250-or 550-sheet
trays (standard
or optional
Optional
2000-sheet
tray
Multipurpose
feeder
Paper size
Dimensions
DL Envelope
110 x 220 mm
(4.3 x 8.7 in)
x
Other Envelope
98 x 162 mm
(3.9 x 6.4 in.) to
176 x 250 mm
(6.9 x 9.8 in.)
x
Duplex unit
1
This size appears in the Paper Size menu only when the paper source does not support size sensing or
when size sensing is turned off.
2
Only the standard exit bin supports this size.
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).
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Registration
Aligner
assembly
Sensor (input)
Sensor (input)
The sensor (input) is located just before the print cartridge and can detect whether media exists in the input
path.
Alignment assembly
The alignment assembly is used to feed the media through the input path and to ensure that media is fed
through the machine in a perfectly straight manner and not in a skewed manner. The alignment assembly can
be adjusted to correct media skew issues and should always be adjusted when it is replaced.
Diagnostic aids
3-51
Transfer
Transfer roll
Transfer roll assembly
The transfer roll assembly applies charge to the rear surface of the media when the media passes between the
transfer roll assembly and photo conductor (drum). Thus, the toner image is transferred from the photo
conductor (drum) surface to the media surface.
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Polygon printhead assembly
The printhead scans the photo conductor drum surface with a laser beam. It consists of four components: laser
diode (LD) card assembly, printhead motor, polygon mirror, and the start of scan card assembly.
Polygon printhead
1. LD card assembly — generates the laser beam. The beam is turned on or off according to a print data
signal coming from the system card.
2. Printhead motor/polygon mirror — the polygon mirror is mounted to the shaft of the printhead motor, and is
rotated at a high speed by the printhead motor. The mirror rotation shifts the incidence and reflection
angles of a laser beam to scan the photoconductor (drum) in a single direction. The laser beam reaches
the polygon mirror as it passes through multiple lenses, mirrors, 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 off the beam, one line of latent image is created. If the scanning by the laser beam is repeated
while rotating the drum, a two-dimensional image is created. The resolution in the scanning direction (from
right to left) is determined by the rotational speed of the printhead motor, depending on how quickly the laser is
adjusted. The resolution in the process direction (from top to bottom) is determined by the rotational speed of
the printhead motor. (The higher the scanning speed becomes, the sooner the scanning of the next row can be
started.)
Diagnostic aids
3-53
Conceptual diagram of an image created by scanning
Fuser
Fuser unit assembly
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Fuser components
Heat roll
The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The
heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media.
Diagnostic aids
3-55
Pressure roll
The pressure roll is used to apply pressure to the media surface for fusing. Pressure is applied to the media
between the pressure roll and heat roll, pressing the melted toner against the media.
Heater lamp
The heater lamp is a quartz glass tube containing a heater coil. A terminal is mounted to the end of the heater
rod via a harness.
Thermal cutoff
If the heat roll temperature exceeds the preset temperature, the thermal cutoff cuts off 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 point.
Sensor (narrow media)
The sensor (narrow media) detects the arrival of narrow media at the detection point in the exit area of the
fuser, and also detects the ejection of media from this point. It is used to make adjustments to ensure that
narrow media is properly fused.
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Fuser unit assembly (type 1 and type 2)
Type 1 fuser unit assembly
In the type 1 fuser unit assembly, the detacs, which are used to prevent the media from sticking to the hot roll,
do not make contact with the hot roller. The type 1 fuser unit assembly has a life of 300K.
Hot roll
Fuser lamp
Non contact detac
Pressure roll
Hot roll
Non contact detac
Pressure roll
Type 2 fuser unit assembly
In the type 2 fuser unit assembly, the detacs, which are used to prevent the media from sticking to the hot roll,
do make full contact with the hot roller. The type 2 fuser unit assembly has a life of 150K.
Fuser lamp
Hot roll
Full contact detac
Pressure roll
Hot roll
Full contact detac
Pressure roll
Diagnostic aids
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Exit
The standard media exit ejects printed media from the printer to the standard bin .
Sensor (standard bin full)
The sensor (standard bin full) detects whether the standard bin is full by moving the actuator up and down.
Drive
Main drive motor assembly
The main drive motor is a DC motor that drives the print cartridge, aligner, MFP and fuser.
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Redrive motor assembly
The redrive motor assembly is a DC motor that drives the redrive assembly that transports the media into the
standard bin or output option.
Redrive motor
assembly
Main drive
motor assembly
Electrical components and controller
Main cooling fan
LVPS card
assembly
LVPS
cooling fan
System card
assembly
Print cartridge
cooling fan
HVPS card
assembly
Switch (printer front door interlock)
Diagnostic aids
3-59
The switch is a safety switch to cut off a 24 VDC power supply from the LVPS card assembly to the high volt
power supply (HVPS) card assembly, printer system card assembly and to the main drive motor assembly,
while the printer front door assembly is open.
Main cooling fan
The main cooling fan discharges air from the printer to prevent excessive temperature increase.
Print cartridge cooling fan
The print cartridge cooling fan discharges air from the print 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 machines.
LVPS cooling fan
The LVPS cooling fan discharges air from the LVPS to prevent excessive temperature increases
HVPS card assembly
The HVPS card assembly generates AC power and feeds it to the developer roll, the transfer roll assembly and
the charge roll assembly.
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System card assembly
The system card assembly controls printing operation based on the communication with the RIP controller and
optional peripherals. It also controls toner dispense, fuser control, sensor switch feedback, drive motors,
clutches and solenoids
Control
Printhead control
Rotation of printhead motor
The on/off control of the printhead motor is performed according to the mode of operation as shown below.
Operation mode
PRINTHEAD motor on/off
Standby mode
Always off
Print mode
Turns on upon receiving the signal from the controller,
and turns off after a preset time has passed from the
end of printing. Also turns off if a print command is not
received within 30 seconds from the reception of the
signal.
Sleep mode
Always off
Determination of printhead ready
The printhead goes into ready state after the specified period passes since the reception of the printhead MPA
start signal and the SOS cycle exceeds the reference value.
Printhead reference value
Printhead reference value
Description
Ready reference value
SOS signal interval (equivalent to 98% or more of the rated RPM of the
printhead motor)
Fail reference value
SOS signal interval (less than 98% of the rated rpm of the printhead
motor)
Fuser control
Fuser control method
The on/off control of the main/sub heater lamps is performed based on the fuser control temperature. The fuser
transmits between the five states (warm up, ready, standby, print, and low power) depending on 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 roll surface temperature (fuser temperature) to regulate the temperature at the
target control temperature by turning on or off the heater lamp.
Diagnostic aids
3-61
Fuser warm-up
The fuser warm-up starts at the time of power on, interlock open or close, jam reset, or return from the low
power mode, and ends when the ready temperature is attained, when a failure occurs, or when executing
diagnosis.
Xerographic and print cartridge components
3-62 Service Manual
Charge
The Charge Roll places a uniform negative electrostatic charge on the surface of the drum. The drum surface
is made of a photoconductive material that holds an electrical charge as long as the drum remains in darkness.
Light striking the drum discharges the surface charge.
HVPS
(-VDC)
Charge roll
(-VDC)
Ground
DRUM
Photoconductive
Surface
Drum Surface
Image
Drum Surface
Voltage
-VDC value
Conductive Tube
Ground
0V
Exposure
The Printhead generates a beam of laser light. Image data received from the system card assembly modulates
this beam, turning it on and off 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 and
slightly less negative than the surrounding negative charge. The less negative areas are considered positive.
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This discharge/no discharge process creates an invisible, electrostatic image on the surface of the drum. This
image is called a latent image.
Modulated
Laser Beam
Printhead
DRUM
Drum Surface
Image
Drum Surface
Voltage
Laser Beam
Laser Beam
Discharge
Level
Invisible Latent Image
0V
Development
The toner contained within the PC Cartridge has an electrical property that causes it to adhere to the
development roll. The Metering Blade spreads the toner into a very thin layer on the development roll. Friction
between the development roll and the CM Blade development roll generates a small electrical charge that is
transferred to the toner.
The surface of the developer Roll is made up of a thin sheet of conductive material. The HVPS supplies the
development Roll with two voltages: a DC voltage and an AC voltage. The DC voltage is used to transfer toner
from 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 lower relative negative value, than the development roll. A
discharged point on the surface of the drum now appears less negative in relation to the negative charge on
the development roll.
The toner adhering to the development Roll is always in contact with the drum surface. When a less negative
point on the drum (a discharged area) comes in contact with the more negative charged toner on the Magnet
3-64 Service Manual
Roll, toner transfers from the Magnet Roll to that point on the drum. There is now a visible toner image on the
drum surface. The image is called a developed image.
Developer
Roll
HVPS
Metering
Blade
Toner
DRUM
-VDC
Drum Surface
Image
Drum Surface
Voltage
Toner at
-VDC Developer
Bias value
0V
Discharge
Level
Visible Developed Image
Transfer
As the paper travels between the transfer Roll and the photoconductor (drum), the Transfer Roll applies 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
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3-65
negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the
paper.
HVPS
-VDC
-VDC
DRUM
Transfer roll
Sheet of paper
Cleaning
The Cleaning Blade removes any toner that remains on the drum after the transfer process. The toner that the
Cleaning Blade removes is collected inside the sealed PC Cartridge.
Used Toner
Cleaning Blade
Charge roll
DRUM
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Auto density sensing
The image density sensor assembly uses a reflection type sensor that detects a pre-placed toner patch and
image on the photoconductor (drum) and outputs pulses when the central line of the patch image aligns with
the central line of the detector. The sensor outputs pulses at the timing the patch image passes the sensor.
Therefore, observing changes of intervals at which pulses are output leads to toner density detection.
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Document scanning at ADF
The document scanning section of this machine consists of a scanner that reads a single-sheet document
placed on the platen glass and a document feeder that can transport a multiple-sheet document for one or twosided scanning.
Document scanning at platen
Shown below is the operational overview of document scanning at the platen.
The scanner CCD assembly travels to read the document.
The exposure lamp is installed on the scanner CCD assembly. As the scanner CCD assembly travels, the
document on the platen glass is scanned and exposed with the exposure lamp.
The image data is read with the scanner 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.
ADF Scan position
Platen registration point
Carriage
Sensor (scanner HP)
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), Sensor (FB length APS 2), Sensor (FB length APS 3)
The document length in the slow scanning direction is detected by a combination of the three reflector sensors.
Switch (ADF closed interlock)
A switch that detects whether the ADF is open and determines the timing of platen document size detection.
Scanner drive motor assembly
A stepping motor that drives the scanner CCD assembly.
3-68 Service Manual
Sensor (FB scanner HP)
A sensor that detects the HP position of the flatbed scanner CCD assembly.
Scanner exposure lamp
A xenon lamp to which the document is exposed.
Scanner controller card assembly
A card that controls the scanner section.
Scanner cooling fan
A fan that prevents overheating of the scanner controller card assembly and exposure lamp.
Interface card
Cooling fan
CCD carriage
Motor
Paper length sensor
H.P. sensor
A document sheet set in the document tray assembly is fed through the ADF feed roll, ADF pick roll, and ADF
separation roll assembly. The document image is scanned at the scan position, and the document sheet is
ejected through the ADF feed-out roll assembly and the ADF exit roll assembly. For a duplex document sheet,
the image on side 1 and the image on side 2 are scanned at the same time in the same pass.
Described below is 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 properly, turning on the document set
LED.
Preparation for feed
Pressing the start button with the document set in the document tray will start feeding the document.
First the pick roll moves down and presses the document on the document tray to enable document feed.
The pick roll moves down with the normal rotation of the ADF feed drive motor assembly and it moves up with
the reverse rotation of the ADF feed drive motor assembly.
Upon completion of document feed, the pick roll returns to the normal (raised) position.
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Shown below is the document feed path from the ADF.
Duplex CCD
Simplex and duplex document feed
For two simplex document sheets, feed is performed in the following sequence:
1. The first document sheet is fed to the ADF transport roll assembly.
2. The document is fed to the ADF registration roll assembly, and then fed to the scan feed reference
position.
3. The document sheet is fed at the feed speed corresponding to the selected magnification, and the image
on it is scanned with the exposure lamp at the scan position.
4. As the image 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 document sheet is fed to the ADF transport roll assembly.
2. The document is fed to the ADF registration roll assembly, and then fed to the scan feed reference
position.
3. The document sheet is fed at the feed speed corresponding to the selected magnification, and the image
on it is scanned with the exposure lamp at the scan position.
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4. As the image is scanned on both sides, the document sheet is fed and ejected by the ADF feed-out roll
assembly and ADF exit roll assembly that are driven by the ADF transport motor.
Transport motor
Pick roll
Feed motor
Exit roll assembly
Names and functions of components
ADF
Sensor (ADF long media)
The document length in the slow scanning direction is detected by this sensor.
Sensor (ADF width 1), Sensor (ADF width 2), Sensor (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 Tray.
Switch (ADF top door interlock)
A switch that detects whether the ADF top door assembly is open.
ADF controller card assembly
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3-71
A card that controls the ADF unit assembly. The ADF controller card assembly is connected to and controlled
by the Scanner controller card assembly.
Sensor (ADF sheet through)
The ADF sensor (ADF sheet through) is installed immediately downstream from the Feed/pick roll assembly to
detect completion of document feed.
Sensor (ADF 1st scan)
The ADF sensor (ADF 1st scan) is installed just upstream of the scanning surface and is used to for scanning
timing operations.
Sensor (2nd scan)
The ADF sensor (ADF 1st 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 in the normal direction (CW direction).
When this motor rotates in the reverse direction, the ADF transport roll assembly stops.
ADF transport motor
The ADF transport motor is a stepping motor that rotates the ADF registration roll assembly, ADF feed-out roll
assembly, and ADF exit roll assembly.
ADF pick solenoid assembly
3-72 Service Manual
This solenoid causes the ADF pick roll to be raised and lowered in order to properly pick the media.
Sensor (ADF media length)
Sensor (ADF media width)
Sensor (Media exit)
Sensor (ADF document set)
Sensor (ADF lower
door interlock)
ADF pick solenoid
Switch (ADF
closed interlock)
Sensor (ADF top
door interlock)
Sensor (ADF rear registration)
Sensor (ADF front registration)
Sensor (ADF sheet through)
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3-73
High Capacity Input Tray (HCIT) tray assembly
Rear media tray guide
Media end guide
Pick arm
assembly
Media size
actuator
Sensor (media empty)
Sensor (media low)
Sensor
(pass through)
Sensor
(tray raised HP)
HCF drawer
assembly
Tray lift drive motor
3-74 Service Manual
250-sheet/550-sheet tray assembly
Lockable back restraint
Rear media tray guide
Media end guide
Auto size finger actuator
Media size sensing
The media size set for the media tray assembly is set by positioning the right media guide, unlocking the slider
lock, and sliding the rear paper guide. The rear paper guide triggers the movement of the auto size sensing
finger, which then sets the switches of the controller card board. The combination of ON/OFF position of the
three switches provides information of the media sizes to the engine.
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
Note: Media size sensing through ON/OFF switch combination
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Media level sensing
The media level for the media tray assembly is triggered by the actuator flag positioned in the two
photointerrupter sensors in the pick arm bracket assembly. The actuator flag blocks and unblocks the two
sensors in different sequence; it determines whether the paper tray is empty, low, or full.
250-sheet tray
Sensor A
Sensor B
Tray full
unblocked
unblocked
Tray low
blocked
unblocked
Tray empty
blocked
blocked
550-sheet tray
Sensor A
Sensor B
Tray full
unblocked
blocked
Tray low
blocked
blocked
Tray empty
blocked
unblocked
Note: Media level sensing through sensor blocking sequence
Pick motor
The pick motor is activated to provide downward 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 the next media.
3-76 Service Manual
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)
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Media transport path
The following is a cross section of the printer and the tandem tray module, showing the main components directly
associated with the media path and transport.
Models X651, X652/5535dn, X654, and X656 paper path rolls and sensors
PC drum
Sensor (input)
Standard bin full actuator
and sensor (standard bin full)
Diverter
PC cartridge
Sensor (fuser output)
Sensor (narrow media)
Sensor (option
pass through)
Sensor
(duplex input)
Pick arm
assembly
3-78 Service Manual
Model X658 paper path rolls and sensors
PC drum
Sensor (input)
Standard bin full actuator
and sensor (standard bin full)
Diverter
PC cartridge
Sensor (fuser output)
Sensor (narrow media)
Sensor (option
pass through)
Sensor
(duplex input)
Pick arm
assembly
Functions of main components
When the 250 or 550 sheet input trays are installed under the printer, additional trays are available.
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.
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
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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 feed media.
Media tray assembly
Rear media guide
Bottom plate
End guide
Detection of media size
The media size set for the media tray assembly is transmitted to the switch (media size) by moving these
guides. The media size is detected by the on/off information of these switches.
Pick arm assembly
Since all media trays are functionally equivalent in terms of the switch (media size), sensor (media empty),
sensor (media low), only the components of one tray are described here.
The pick arm assembly is a mechanical unit supplying media from the media tray assembly to the printer. The
driving force, from the pick arm drive motor on the pick arm assembly, is transmitted to the two pick rolls to
feed media.
When 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, it picks very
gently. If a heavy media is used, it picks very aggressively. No customer adjustments are necessary, therefore
no special trays are needed for card stock or labels. The gearing in the arm is designed so the input torque
from the motor produces a movement about the pivot of the arm. 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
paper is physically held and not allowed to feed, then the motor stalls. Slippage between the roll and the paper
is theoretically impossible. When the motor is energized, the pick rolls are driven down into the stack,
increasing the normal force and drive force until the bending strength of the paper is overcome and the paper
bends and moves up the wear strip.
3-80 Service Manual
Switch (media size)
This switch (media size) sets the size of media supplied from each media tray assembly. A signal indicating the
media size is transmitted as a voltage to the printer system card assembly.
Sensor (media empty)
If media runs out in a media tray assembly, the actuator lowers and the actuator flag, unlocks the sensing area
of the sensor (media empty). The sensor light is transmitted. When the sensing area is blocked (media is
present), the signal is off.
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
Rear media guide
Bottom plate
End guide
Note:
Analog switch
Media Size
S/W1
S/W3
No Tray
Off
Off
B5L/7.25” x 10.5”L
Off
On
8.5” x 11”L
On
Off
A4L
On
On
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Duplex
Functions of main components
When the duplex is installed, duplex (double-sided) printing is available with the printer.
The following outlines the functions of the main components of the duplex.
Sensor (duplex input)
The sensor (duplex wait) detects whether media is remaining in the duplex.
Duplex drive motor assembly
The duplex drive motor assembly transmits driving force to the two duplex media transport roll assemblies and
the duplex media center transport roll assembly middle that feeds media.
Duplex drive
motor assembly
Sensor (duplex input)
3-82 Service Manual
Paper jams
Understanding jam numbers and locations
When a jam occurs, a message indicating the jam location appears. Open doors and covers and remove trays
to access jam locations. To resolve any paper jam message, you must clear all jammed paper from the paper
path.
The following table lists the jams that can occur and the location of each jam:
8
8
1
1
6,7
2
4
2
4
5
3
3
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
Stapler
8
290–294
ADF cover
200 and 203 paper jams
1. Touch Status/Supplies to identify the location of the jam.
2. Lower the multipurpose feeder door.
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3. Push the release latch, and then open the front cover.
3
4. Lift and pull the print cartridge out of the printer.
Warning: Do not touch the photoconductor drum on the underside of the cartridge. Use the cartridge handle
whenever you are holding the cartridge.
5. 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.
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6. Remove the jammed paper.
CAUTION: The inside of the printer might be hot. To reduce the risk of injury from a hot component,
allow the surface to cool before touching.
Note: If the paper is not easy to remove, then open the rear door and remove the paper from there.
7.
8.
9.
10.
Align and reinstall the print cartridge.
Close the front cover.
Close the multipurpose feeder door.
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.
230–239 paper jams
1. Touch Status/Supplies to identify the location of the jam.
2. Pull the standard tray out.
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3. Pull down the bottom rear door.
4. Push the tab down.
5.
6.
7.
8.
Remove the jammed paper.
Close the bottom rear door.
Insert the standard tray.
Touch Continue.
3-86 Service Manual
240–245 paper jams
1. Touch Status/Supplies to identify the location of the jam.
2. Pull the standard tray out.
3.
4.
5.
6.
7.
Remove any jammed paper, and then close the tray.
Touch Continue.
If the jam message remains, then pull out any optional trays.
Remove the jammed paper, and then insert the trays.
Touch Continue.
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250 paper jam
1. Touch Status/Supplies to identify the location of the jam.
2. Remove the paper from the multipurpose feeder.
3. Flex the sheets of paper back and forth to loosen them, and then fan them. Do not fold or crease the paper.
Straighten the edges on a level surface.
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.
ABC
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. Lift the envelope weight.
2. Remove all envelopes.
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3. If the jammed envelope has entered the printer and cannot be pulled out, then lift the envelope feeder up
and then out of the printer, and then set it aside.
4. Remove the envelope from the printer.
Note: If you cannot remove the envelope, then the print cartridge will have to be removed. For more
information, see “200 and 203 paper jams” on page 3-83.
5.
6.
7.
8.
9.
10.
Reinstall the envelope feeder. Make sure it snaps into place.
Flex and stack the envelopes.
Load the envelopes in the envelope feeder.
Adjust the paper guide.
Lower the envelope weight.
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 step 3.
3. Pull down the output bin door or doors.
4. Remove the jammed paper.
5. Close the output bin door or doors.
6. Touch Continue.
28X staple jams
1. Touch Status/Supplies to identify the location of the jam.
2. Press the latch to open the stapler door.
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3. Pull the latch of the staple cartridge holder down, and then pull the holder out of the printer.
4. Use the metal tab to lift the staple guard, and then remove any loose staples.
5. Close the staple guard.
3-90 Service Manual
6. Press down on the staple guard until it snaps into place.
7. Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place.
8. Close the stapler door.
290–294 paper jams
1. Remove all original documents from the ADF.
2. Open the ADF cover, and then remove any jammed paper.
3. Close the ADF cover.
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4. Open the scanner cover, and then remove any jammed pages.
5. Open the bottom ADF door, and then remove any jammed pages.
1
2
6. Close the bottom ADF door and scanner cover.
7. Touch Restart Job.
3-92 Service Manual
Adjusting skew
For flatbed scanner and ADF skew adjustment, refer to the examples below to identify if “negative” or “positive”
skew is present; this will help with determining the correct adjustment to be made.
Acceptable ADF and flatbed scanner specifications
Scan
Flatbed (LE, TE, left & 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%
Diagnostic aids
3-93
Flatbed scanner skew adjustment
1. Remove the scanner cover, left. Go to “Scanner cover, left removal (models X651, X652/5535dn,
X654, and X656)” on page 4-134 or “Scanner cover, left removal (model X658)” on page 4-135.
2. To adjust flatbed scanner skew, loosen the screws (A) and slide the scanner rod mounting plate left or right
accordingly and retighten screws (A).
A
ADF skew adjustment (via ADF document tray)
1. Remove the ADF cover front and ADF cover, rear. Go to “ADF cover, front removal” on page 4-64 and
“ADF cover, rear removal” on page 4-65.
2. Loosen the screws securing the ADF document tray on either side.
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3. For negative skew, rotate the document tray clockwise as shown above.
4. For positive skew, rotate the document tray counterclockwise as shown above.
5. After skew correction has been made, tighten the document tray screws, and reinstall the ADF front and
rear covers.
Diagnostic aids
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ADF skew adjustment (Via duplex CCD assembly)
1. Remove the ADF cover, front. Go to “ADF cover, front removal” on page 4-64.
3-96 Service Manual
2. Loosen the M4 screw (A) on the right below.
3. Turn the skew adjustment screw (B) (to the left, below) appropriately - clockwise for negative skew and
counterclockwise for positive skew.
Note: Each full turn of the adjustment screw yields .5 mm of skew correction. The maximum adjustment is
three turns for clockwise movement of the screw, and four turns for counterclockwise movement.
A
B
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 with its roller.
Diagnostic aids
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Media squareness check
This test is critical when cut paper is being used to align the ADF skew during reworks. Pallets of quality paper
may be found with more than 2 mm of skew.
1. Remove two consecutive pieces of paper from the ream.
1
2
2. Flip one of the pages over in the direction shown below.
Long Edge
2
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1
3. This shows the final position of the two pages.
1
4. Tap the two pages on a flat surface until the bottom edge is aligned.
Diagnostic aids
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5. Look closely at the top edge of the media to see if the sheets are aligned.
Square Media: Top and sides
are perfectly aligned
The two pages do not align perfectly at the top or sides.
Media Not square: DO NOT use for ADF skew rework.
3-100 Service Manual
Print skew correction procedure
1.
2.
3.
4.
5.
Check the paper squareness.
Make sure the guides in the paper tray are properly aligned.
Check the base printer skew and registration.
Plug printer into the power source and power on in Diagnostics Mode (hold down 3 and 6 during POR).
Measure L1, L2, T1, T2, R1, R2, B1, and B2 data points as shown below.
T1
T2
L1
R1
L2
R2
B1
B2
6. Determine the following calculations:
• L2-L1 = ___
• R2-R1 = ___
• T2-T1 = ___
• B2-B1 = ___
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7. Determine if the printer passes or fails the skew specifications based on the values listed on the table..
Skew Specification
(L2-L1)
(R2-R1)
(T2-T1)
(B2-B1)
Letter
1.4 mm
1.4 mm
1 mm
1 mm
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.
9. Check the registration by looking at the dots at the edges of the page. Adjust as needed.
3-102 Service Manual
Copy skew correction procedure
Note: This specification is used for copies from the flatbed, front ADF, and back ADF.
1.
2.
3.
4.
5.
6.
7.
Check the paper squareness.
Make sure the guides in the paper tray are properly aligned.
Check the printer skew and registration.
Make sure the page is pushed to the top left corner of the flatbed.
Make sure the autodocument guides are snug against the page.
Plug printer into the power source and power on in Normal Printing Mode.
Measure CopyL1, CopyL2, CopyT1, CopyT2, CopyR1, CopyR2, CopyB1, and CopyB2 data points as
shown below.
CopyT1
CopyT2
CopyL1
CopyR1
CopyL2
CopyR2
CopyB1
CopyB2
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 = ___
• CopyT2-CopyT1 = ___
• CopyB2-CopyB1 = ___
• CopyT1-CopyB1 = ___
• CopyL1-CopyR1 = ___
Diagnostic aids
3-103
10. Determine if it passes or fails the skew specifications, based on the values listed in the table.
Copy Skew Specification
Measurement
Specification
Description
(CopyL2-CopyL1)
2.0 mm
Left Skew
(CopyR2-CopyR1)
2.0 mm
Right Skew
(CopyT2-CopyT1)
1.5 mm
Top Skew
(CopyB2-CopyB1)
1.5 mm
Bottom skew
Measurement
Specification
Description
(CopyT1-CopyB1)
3.0 mm
Vertical Registration
(CopyL1-CopyR1)
4.0 mm
Horizontal Registration
Copy Registration Specification
11. Adjust the skew as specified in “Adjusting skew” on page 3-93 as needed.
12. Adjust the scanner registration manually as needed in the Configuration Menu.
3-104 Service Manual
Security Reset Jumper
The Security Reset Jumper is available on all high-end printer and MFP models, including the T650, T652,
X652/5535dn, X654, X656, and X658.
It functions as described below (excerpt from the RIP Functional Spec):
Security Reset Jumper
Each device contains a hardware jumper with which an administrator can:
• Erase all security templates, building blocks, and access controls that a user has defined (i.e. the factory
default configuration); or
• Force the value of each function access control to “No Security” (all security templates and building blocks
are preserved but not applied to any function).
Note: Note: If the “Enable Audit ” setting in the Security Audit Log section of the “Security Menu ” is activated,
the device logs a message each time that the jumper is used.
A small lock icon identifies the jumper’s position on the RIP card. Also, to make it easier to separate the small
yellow plastic jumper from the 3-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 completely negate the effects of a jumper reset, an
administrator can select the “No Effect ” value for the jumper-related setting on the Security Web page or in the
“Security Reset Jumper ” setting in the “ Security Menu”.
To perform a jumper reset operation:
1. Power the device off.
2. Remove the Kensington lock from the card cage (if installed).
Diagnostic aids
3-105
3. Remove the small yellow jumper that covers a pair of the jumper’s pins.
Top
Rear
Front
Bottom
4. Replace the small yellow jumper so that it covers the pins adjacent to its original position.
5. Replace and secure the Kensington lock on the card cage (if installed).
6. Power the device on.
Note: The movement of the small yellow jumper from position A to position B triggers the reset, not the
specific positions. When the device is powered on, it labels the current position of the small yellow jumper (let’s
say position A) as the “home ” position. If, at the next POR, the device detects that the small yellow jumper has
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->Security->Edit Security Setups menu. These are all the PINs, Passwords, and
other Building Blocks and Security Templates that define the device's protection of functions and menus. In
other words, if the customer is using LDAP to authenticate users to use the Copy function, then after the RIP
card is replaced, the device will no longer have that LDAP configuration or the Copy function protected.
3-106 Service Manual
Printer skew specifications
Abnormal skew printer correction
STEP ONE: The repair operator should ev aluate the left edge of the paper to determine if the aligner is
properly set. If the left vertical line is with the defined limit, parallel to the edge of the paper, the aligner is
correct and properly set. If the left edge vertical line is not within the defined limit spec the repair operator can
adjust the aligner at the repair station.
STEP TWO: The repair operator should evaluate the horizontal line at the top edge of the page for potential
LSU induced skew. If the horizontal line does not fall within the defined limit or spec, then it is considered
skewed and the printhead must be adjusted. Go to “Polygon printhead mechanical registration
adjustment” on page 4-2.
Quick Test
Quick Test
Printer Information
Page Count
PSAC
Installed Memory
Processor Speed
Serial Number
CalStat
CalSet
xx
xx
xxx MB
xxxMHz
xxxxxxx
xxxx
x.xx x.xx x.xx
x.xx x.xx
Engine ID
xx
FSpeed
xxx
Printer Rev isi on Lev els
Loader
xx.xx.xxxx-x
Kernel
xxx.xx.xxxx-x
Base
xx.xx.xxxx-x
Network
xxx.xx.xxxxx-x
Network Drvr
xx.xx.xxxx-x
Engine
xx.xx.xxxx-x
Font
x.xxxxx-xx.x
Printer Information
Margin Settings
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
Formatted Size
= Tray 1
= xxxxxx
Straight
Page Count
xx
PSAC
xx
Installed Memory
xxx MB
Processor Speed
xxxMHz
Serial Number
xxxxxxx
CalStat
xxxx
CalSet
x.xx x.xx x.xx
x.xx x.xx
Engine ID
xx
FSpeed
xxx
Pri nter Revisi on Leve ls
Loader
xx.xx.xxxx-x
Kernel
xxx.xx.xxxx-x
Base
xx.xx.xxxx-x
Network
xxx.xx.xxxxx-x
Network Drvr
xx.xx.xxxx-x
Engine
xx.xx.xxxx-x
Font
x.xxxxx-xx.x
Margin Settings
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
Formatted Size
= Tray 1
= xxxxxx
Skewed
Printhead Skew + Paper Feed Skew
Diagnostic aids
3-107
Duplex Skew Specification
Side:
1
2
2nd
1st
+/-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-Web Paper
- Vinyl, Polyester
(less than or equal 92# liner
+/-0.010 mm/mm
+/-0.010 mm/mm
+/-0.010 mm/mm
+/-0.010 mm/mm
Print Sequence Thru Printer:
16 lb-to-24 lb
Print Registration
Initial adjustment (adjustable in increments of T=0.3mm, B-0.5mm, R and L=0.2mm
Left print position accuracy (scanning direction): +/-0.5mm - start on scan
Top print position accuracy (feeding direction): +/-0.5 mm - start on scan
Horizontal page width accuracy: +/-0.5mm - mirror motor
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
3-108 Service Manual
4. Repair information
Warning: Read the following before handling electronic parts.
Handling ESD-sensitive parts
Many electronic products use parts that are known to be sensitive to electrostatic discharge (ESD). To prevent
damage to ESD-sensitive parts, use the following instructions in addition to all the usual precautions, such as
turning off power before removing logic boards:
• Keep the ESD-sensitive part in its original shipping container (a special “ESD bag”) until you are ready to
install the part into the machine.
• Make the least-possible movements with your body to prevent an increase of static electricity from clothing
fibers, carpets, and furniture.
• Put the ESD wrist strap on your wrist. Connect the wrist band to the system ground point. This discharges
any static electricity 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 grounds. They increase the risk of damage, because they
•
•
•
make a discharge path from your body through the ESD-sensitive part. (Large metal objects can be
discharge paths without being grounded.)
Prevent ESD-sensitive parts from being accidentally touched by other personnel. Install machine covers
when you are not working on the machine, and do not put unprotected ESD-sensitive parts on a table.
If possible, keep all ESD-sensitive parts in a grounded metal cabinet (case).
Be extra careful in working with ESD-sensitive parts when cold-weather heating is used, because low
humidity increases static electricity.
Repair information
4-1
Adjustments
Polygon printhead mechanical registration adjustment
Do the printhead mechanically registration adjustment whenever you remove or replace the printhead or loosen
the mounting screws.
Install the new printhead with the mounting screws centered in the slots in the printhead frame assembly. Leave
the screws loose enough to allow the printhead to move from side to side within the slots. It is necessary to
perform a mechanical registration adjustment before locking down the three printhead mounting screws.
Note: In the case of paperfeed skew, go to “Alignment assembly adjustment” on page 4-3.
To perform the mechanical registration adjustment:
1. Turn the printer off.
2. Press and hold 3 and 6 to enter the diagnostic mode.
3. Turn the printer on, and release the buttons when Performing Self Test displays.
4. Select Registration from the menu.
5. Select Quick Test Page. The test page should only be printed on letter or A4 paper from Tray 1. The Quick
Test Page consists of alignment diamonds, horizontal lines that can be used for mechanical registration
adjustment. An example of the printhead alignment printout is shown below:
Quick Test
Device Information
31
192 MB
467MHz
Page Cou nt
Installed Memory
Processor Speed
Serial Number
TDS Calibration
Engine ID
System Card ID
0116413
00 14 FF 00 00 00 00
40
0004007E24A2
Printer Revision Levels
LF.LBH.P055-0
FFN.APS.F191a-0
LF.LBH.P055-0
NF.APS.N179-0
LF.LBH.P055-0
AF.LB.E037-0
9.9
8.31M02-U5.0
Loader
Kernel
Base
Network
Netwrk Drvr
Engine
Panel
Font
Printer Margin Settings
Top Margin
Bottom Margin
Left Margin
Right Margin
Dup Top Margin
Dup Left Margin
=
=
=
=
=
=
5
0
-3
0
0
0
Paper Source
Formatted Size
= Tray 1
= Letter
- 12
- 10
- 8
- 6
- 4
- 2
0
+2
+4
+6
+8
+ 10
+ 12
Darkest bar indicates
ADJUSTMENT AMOUNT
for bidirectional alignment
Check the Quick Test Page for any sign of misalignment by checking the diamonds at the top left and top
right of the test page for equal distance from the top of the page. If necessary, rotate the printhead to the
left or right and tighten down the mounting screws and check for proper alignment again by running another
Quick Test Page. This procedure may take two or three attempts before you get satisfactory results.
6. When you have the correct adjustment, ensure that the printhead mounting screws are properly tightened.
4-2 Service Manual
Alignment assembly adjustment
Note: Power the machine off before performing the adjustment.
Note: In order to make the adjustment, the side cover, left must first be removed to access the adjusting hole
in the system card.
Do the alignment assembly adjustment whenever you replace the alignment assembly. It may also be
necessary to perform a printhead adjustment after making the media skew adjustment. Always print a copy of
the Quick Test Page before making any adjustments to the alignment assembly reference adjustment screw.
When replacing the alignment assembly, it is necessary to back the reference adjustment screw out far
enough to remove the old assembly and install the new one.
• If you are replacing the alignment assembly, go to step A.
• If you are only adjusting the reference adjustment screw, go to step B.
Step A
Print a copy of the Quick Test Page and check the margin adjustments printed on the test page. These settings
should be within the range specified in “Registration” on page 3-51.
Do the reference adjustment if you are sure the margins are set correctly.
1. Loosen the locknut on the inside rear of the alignment assembly.
2. Remove the two screws holding the alignment assembly to the left side frame.
3. Back the reference adjustment screw out far enough to allow the alignment assembly to be removed from
the printer. It is not necessary to completely remove the screw.
Nutdriver or
Allen wrench
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 plate, and tighten the nut with a 5.5 mm wrench.
The reference adjustment screw can be adjusted without loosening the nut. Turn the screw clockwise a few
turns and print a copy of the Quick Test Page as you check the diamonds on the left margin. Continue adjusting
the screw as you check the results of each adjustment on a new test page until you obtain the results you want.
Step B
Print a copy of the Quick Test Page, and check the margin adjustments printed on the test page. These settings
should be within the range specified in “Registration” on page 3-51. The reference screw can be adjusted
without loosening the locknut. Turn the screw a few turns, and print a copy of the Quick Test Page as you check
the diamonds on the left margin. Continue adjusting the screw as you check the results of each adjustment on
Repair information
4-3
a new test page until you obtain the results you want.
Fuser solenoid adjustment
Perform the fuser solenoid adjustment whenever you replace the fuser solenoid. Adjust the fuser solenoid while
installed in the printer. Adjust the screw on the eccentric mounted on the solenoid housing to provide an air gap
between the rear of the solenoid stator and the solenoid armature. The solenoid air gap for all models is 4.5 mm
± 0.1 mm.
Gap adjustment
The gap adjustment allows you to increase the 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 255. Adjust the gap setting by using
to select the value. If
GAP=0 displays, it indicates a factory setting to minimum gap. Select a value and run several copies of the
media that displays a curl problem. It may take several tries before improvement is noticed.
Note: This setting has no effect when duplexing.
4-4 Service Manual
Removal procedures
Before starting service work
CAUTION:
Remove the power cord from the electrical outlet before you connect or disconnect any cable
or electronic board or assembly.
CAUTION:
While performing service around the fuser assembly, ensure the fuser area has cooled down.
Note: Some removal procedures require removing cable ties. You must replace cable ties during reassembly
to avoid pinching wires, obstructing the paper path, or restricting mechanical movement.
Note: A wide variety of screws are used; make note of their positions during service.
Repair information
4-5
Charge roll assembly removal
WARNING: When removing the charge roll assembly, avoid touching the charge roll surface.
1. Open the MPF door assembly.
2. Open the operator panel door assembly or the print cartridge door assembly.
3. Detach the left side of the charge roll assembly from the machine.
4. 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.
4-6 Service Manual
Duplex assembly removal
Note: When removing the duplex drive motor assembly, it does not need to be completely removed from the
machine. It may be allowed to gently hang out of the way by the harness.
1. Remove the duplex drive motor assembly. See “Duplex drive motor assembly removal” on page 4-9.
2. Remove the pick arm assembly. See “Pick arm assembly removal” on page 4-29.
3. Remove the four screws (A) securing the duplex assembly to the machine.
4. Remove the harnesses (B) from the clamp.
5. Disconnect the connection (C) from the duplex assembly.
D
B
C
A
Note: When removing the duplex assembly, the lower duplex drive belt (D) will become detached.
6. Remove the duplex assembly.
Replacement Warning: When replacing the duplex assembly, ensure that the lower duplex drive belt (D) is
properly reattached.
Repair information
4-7
Duplex cooling fan removal
1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and
X656)” on page 4-122.
2. Remove the screw (A) securing the duplex cooling fan to the machine.
3. Disconnect the connector (B) from the duplex cooling fan.
B
A
4. Remove the duplex cooling fan.
Replacement Warning: When replacing the duplex cooling fan, ensure that it is installed as shown in the
picture.
4-8 Service Manual
Duplex drive motor assembly removal
1. Remove the fuser access door. See “Fuser access door assembly removal” on page 4-12.
2. Remove the cover assembly, rear lower. See “Cover assembly, rear lower (X654, X656, and X658)” on
page 4-38.
3. Remove the three screws (A) securing the duplex drive motor assembly to the machine.
B
A
Note: When removing the duplex drive motor assembly, the upper duplex drive belt (B) will become detached.
4. Remove the band (C) from the duplex drive motor assembly.
C
5. Remove the cover from the duplex drive motor assembly.
6. Disconnect the connection (D) to the duplex drive motor assembly.
Repair information
4-9
7. Remove the harness (E) from the duplex drive motor assembly.
E
D
Replacement Warning: When replacing the duplex drive motor assembly, ensure that all harnesses are
properly re-routed.
Replacement Note: Ensure the belt is replaced properly.
Duplex input sensor assembly removal
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.
A
B
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 the front left duplex guide spring (A) from the duplex guide assembly, front.
4-10 Service Manual
4. Detach the front right duplex guide spring (B) from the duplex guide assembly, front.
A
B
5. Fully open the duplex guide assembly, front 90°, and detach it from the machine.
6. Remove the duplex guide assembly, front.
Repair information
4-11
Media turn guide removal
1. Remove the MPF tray door assembly. See “Operator panel assembly removal (model X658)” on
page 4-109 or “MPF tray door assembly removal (models X651, X652/5535dn, X654, and X656)”
on page 4-97.
2. Gently bend the left side of the media turn guide to release the hook (A) as shown in the picture.
A
3. While gently bending the media turn guide, move the media turn guide in the direction of the arrow.
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
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36.
4-12 Service Manual
2. Press the two tabs (A) on the fuser access door assembly, and detach it from the machine.
A
A
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.
Repair information
4-13
Main cooling fan removal
1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
2. Remove the six screws (A) securing the metal shield to the machine.
A
3. Move the metal shield in the direction of the arrow.
4. Remove the metal shield.
5. Remove the two screws (B) securing the fuser cooling fan to the machine.
6. Remove the fuser cooling fan.
4-14 Service Manual
7. Remove the fuser cooling fan connection (C).
B
C
Fuser drive release linkage removal
1. Remove the system card assembly. See “System card assembly removal” on page 4-50.
2. Gently unsnap the upper end of the fuser drive release linkage from the machine.
3. Rotate the fuser drive release linkage 90° to release the lower end of the fuser drive release linkage from the
machine.
4. Remove the fuser drive release linkage.
Fuser unit assembly removal
1. Remove the fuser wiper cover assembly. See “Fuser wiper cover assembly removal” on page 4-16.
2. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36.
3. Open the fuser access door.
4. Press the two buttons (A) on the fuser unit assembly to release it from the machine.
Repair information
4-15
5. While pressing the two buttons (A), pull the fuser unit assembly from the machine.
B
A
Replacement Warning: When replacing the fuser unit assembly, ensure that the electrical connection (B) and
the two buttons (A) are properly secured.
Fuser wiper cover assembly removal
1. Press the button (A) securing the fuser wiper cover assembly to the machine.
A
2. Remove the fuser wiper cover assembly.
4-16 Service Manual
HVPS card assembly removal
1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and
X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121.
2. Remove the four screws (A) securing the HVPS card assembly to the machine.
3. Remove the HVPS card assembly.
4. Remove connection (B) and the two high voltage connections (C) from the HVPS card assembly.
C
B
A
Replacement Warning: When replacing the HVPS card assembly, ensure that the two high voltage
connections (C) are properly replaced.
Inner deflector removal
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.
1. Remove the MPF lift plate assembly. See “MPF lift plate assembly removal” on page 4-25.
Repair information
4-17
2. Release the two hooks (A) securing the lower portion of the inner deflector to the machine.
A
3. Remove the inner deflector.
Replacement Warning: When replacing the inner deflector, ensure that it is properly installed, or jamming will
occur.
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.
4-18 Service Manual
3. Remove the spring.
A
Replacement Warning: When replacing the option drive shaft, ensure that the plastic hook (A) is not
damaged, or the option drive shaft will not remain secured.
Repair information
4-19
Main drive motor assembly removal
1. Remove the system card assembly. See “System card assembly removal” on page 4-50.
2. Remove the fuser drive release linkage. See “Fuser drive release linkage removal” on page 4-15.
3. Close the operator panel door assembly.
4. Remove the four screws (A) securing the main drive motor assembly to the machine.
5. Gently remove the main drive motor assembly.
6. Disconnect the connection (B) from the main drive motor assembly.
A
B
Replacement Warning: Ensure that all electrical connections are properly replaced.
Replacement Warning: When replacing the main drive motor assembly, ensure that the operator panel door
assembly is in the closed position or the main drive motor assembly will not align properly and damage will
occur.
Replacement Warning: When replacing the main drive motor assembly, ensure that all gears and drive
shafts are properly aligned, or damage will occur.
4-20 Service Manual
Alignment assembly removal
WARNING: When replacing the alignment assembly, ensure that the media skew is properly adjusted using
the adjuster screw (C), or jamming will occur. See “Alignment assembly adjustment” on page 4-3.
1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
2. Remove the six screws (A) securing the metal cover to the machine.
A
3. Remove the metal cover.
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.
Repair information
4-21
6. Remove the two screws (B) securing the alignment assembly to the machine.
B
Note: The adjuster screw (C) requires a hex wrench to loosen and tighten.
Note: The adjuster screw (C) can be accessed through the hole (D) in the system card.
7. Completely loosen the adjuster screw (C) securing the alignment assembly to the machine.
8. Remove the alignment assembly.
D
C
Replacement Warning: When replacing the alignment assembly, ensure that the media skew is properly
adjusted using the adjuster screw (C) or jamming will occur. Go to “Alignment assembly adjustment” on
page 4-3.
4-22 Service Manual
Media out actuator removal
1. Remove the pick arm assembly. See “Pick arm assembly removal” on page 4-29.
2. Release the hook (A) securing the media out actuator to the unit.
A
3. Remove the media out actuator.
Media support removal
1. Gently detach the two bosses (A) of the media support from the machine.
A
A
2. Remove the media support.
Repair information
4-23
Tray roller catch assembly removal
1. Remove the media tray.
2. Remove the HVPS card assembly. See “HVPS card assembly removal” on page 4-17.
3. Release the spring from the machine.
Note: The tray roller catch assembly should be removed from the media tray cabinet.
4. Remove the tray roller catch assembly from the machine.
MPF cam gear removal
1. Remove the alignment assembly. See “Alignment assembly removal” on page 4-21.
2. Release the hook (A) securing the gear to the unit.
A
3. Remove the MPF cam gear.
4-24 Service Manual
MPF lift plate assembly removal
1. Remove the media turn guide. See “Media turn guide removal” on page 4-12.
2. Remove the four screws (A) securing the MPF lift plate assembly to the machine.
3. Gently detach the MPF lift plate assembly.
4. Disconnect the connector (B) from the MPF lower deflector assembly.
B
C
A
5. Remove the MPF lift plate assembly.
Replacement Warning: When replacing the MPF lift plate assembly, ensure that the lever (C) is held down
when reinstalling the MPF lift plate assembly, or damage will occur.
Replacement Warning: When replacing the MPF lift plate assembly, ensure that the MPF pick solenoid
assembly does not become damaged.
MPF media out actuator removal
1. Remove the media turn guide. See “Media turn guide removal” on page 4-12.
2. Gently unsnap the MPF media out actuator from the machine.
3. Remove the media out actuator.
Repair information
4-25
MPF pick roll assembly removal
1. Remove the media turn guide. See “Media turn guide removal” on page 4-12.
2. Remove the E-clip (A) securing the MPF print roll assembly to the machine.
3. Remove the plastic washer (B).
B
A
4. Remove the MPF pick roll assembly.
Replacement Warning: When replacing the MPF pick roll assembly, do not touch the rubber surface.
MPF pick solenoid assembly removal
Note: The MPF lift plate assembly can be detached and allowed to hang by the harness. The connection does
not need to be disconnected.
1. Remove the MPF lift plate assembly. See “MPF lift plate assembly removal” on page 4-25.
2. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
3. Remove the six screws (A) securing the metal cover to the machine.
A
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4. Remove the metal cover.
5. Remove the screw (B) securing the MPF pick solenoid assembly to the machine.
B
C
6. Remove the MPF pick solenoid assembly.
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7. Disconnect the connection (C) from the MPF pick solenoid assembly.
C
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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.
A
B
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5. Remove the screw (C) securing the pick arm assembly to the machine.
C
6. Remove the band (D) from the pick arm assembly.
7. Remove the cover from the pick arm assembly.
8. Remove the three connections (E) from the pick arm assembly.
9. Remove the wiring harness (F) from the pick arm assembly.
F
E
D
10. Remove the pick arm assembly.
Replacement Warning: When replacing the pick arm assembly, ensure that the harnesses are properly
re-routed.
Replacement Warning: When replacing the pick arm assembly, ensure that the connections are properly
replaced.
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Pick roll assembly removal
1. Remove the media tray.
2. Gently pull the pick arm assembly down, and release the two hooks (A) securing the two pick roll
assemblies.
A
A
3. Remove the two pick roll assemblies.
Replacement Warning: When replacing the pick roll assembly, do not touch the rubber surface.
Print cartridge cooling fan removal
1. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654, and
X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121.
2. Remove the 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.
B
A
Replacement Warning: When replacing the print cartridge cooling fan, ensure that it is installed as shown in
the picture.
Repair information
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Print cartridge clamp assembly removal
Note: This procedure can be applied to the left or right printer cartridge hold down assembly.
1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and
X656)” on page 4-106 or “Laser cover removal (model X658)” on page 4-104.
2. Remove the screw (A) securing the print cartridge clamp assembly to the machine.
A
3. Remove the print cartridge clamp assembly.
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Print cartridge ID connector assembly removal
1. Remove the print cartridge.
2. Remove the main drive motor assembly. See “Main drive motor assembly removal” on page 4-20.
3. Release the two hooks (A) securing the print cartridge ID connector assembly to the machine.
A
4. Remove the print cartridge ID connector assembly.
5. Disconnect the connection (B) from the print cartridge ID connector assembly.
B
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Printhead assembly removal
WARNING: When replacing the printhead assembly, ensure that the printhead skew is properly adjusted, or
print quality issues will occur. See “Polygon printhead mechanical registration adjustment” on page 4-2.
1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)” on
page 4-106 or “Laser cover removal (model X658)” on page 4-104.
2. Remove the six screws (A) securing the metal cover to the machine.
A
A
3. Remove the metal cover.
4. Disconnect the connections (B) from the printhead assembly.
B
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5. Remove the four screws (C) securing the printhead assembly to the machine.
C
6. Remove the printhead assembly.
Replacement Warning: When replacing the printhead assembly, ensure that the printhead skew is properly
adjusted, or print quality issues will occur. See “Polygon printhead mechanical registration adjustment”
on page 4-2.
Connection access cover, rear removal
1. Gently detach the two hinges (A) of the connection access cover, rear from the machine.
A
2. Remove the connection access cover, rear.
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Door assembly, rear removal
1. Pull the door assembly, rear away from the machine.
2. Twist the door strap left or right until vertical, and pull the strap out of the slot.
3. Position the door assembly, rear at a 45° angle as shown in the picture.
4. Remove the door assembly, rear.
Duplex guide assembly, rear removal
1. Remove the cover assembly, rear lower. See “Cover assembly, rear lower (X654, X656, and X658)” on
page 4-38.
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).
4-36 Service Manual
6. Detach the rear duplex guide spring (C).
B
A
C
7. Remove the duplex guide assembly, rear.
8. Remove the screw (D) securing the rear duplex guide handle to the assembly.
D
9. Remove the duplex guide assembly, rear.
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Cover assembly, rear lower (X654, X656, and X658)
1. Open the rear lower door.
2. Remove the four screws (A) securing the cover assembly, rear lower to the machine.
A
3. Remove the cover assembly, rear lower.
Redrive motor assembly removal
1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)”
on page 4-106 or “Laser cover removal (model X658)” on page 4-104.
2. Remove the six screws (A) securing the metal cover to the machine.
A
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3. Remove the metal cover.
4. Disconnect the connection (B) from the redrive motor assembly.
B
5. Disconnect the connection (C) from the sensor (standard media bin full).
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6. Release the hooks (D) securing the output option interface cable assembly to the machine.
D
C
7. Detach the output option cable assembly.
8. Remove the two screws (E) securing the redrive motor assembly to the machine.
E
9. Remove the redrive motor assembly.
4-40 Service Manual
Sensor (duplex input) removal
1. Remove the duplex input sensor assembly. See “Duplex input sensor assembly removal” on page 4-10.
2. Release the hooks (A) securing the senor (duplex media path) to the bracket.
A
3. Remove the sensor (duplex input).
Sensor (media low) removal
1. Remove the pick arm assembly. Go to “Pick arm assembly removal” on page 4-29.
2. Release the hooks (A) securing the sensor (media low) to the assembly.
A
3. Remove the sensor (media low).
Sensor (media empty) removal
1. Remove the pick arm assembly. See “Pick arm assembly removal” on page 4-29.
2. Release the hooks (A) securing the sensor (media empty) to the assembly.
A
3. Remove the sensor (media empty).
Sensor (toner empty) removal
1. Remove the HVPS card assembly. See “HVPS card assembly removal” on page 4-17.
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2. Remove the screw (A) securing the sensor (toner empty) to the machine.
3. Remove the sensor (toner empty).
4. Disconnect the connection (B) from the sensor (toner empty).
Sensor (input) removal
1. Remove the inner deflector. See “Inner deflector removal” on page 4-17.
2. Release the hooks (A) securing the sensor (input) to the machine.
A
3. Remove the sensor (input).
4. Disconnect the connection (B) from the sensor (input).
Sensor shield assembly removal
1. Remove the inner deflector. See “Inner deflector removal” on page 4-17.
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2. Gently unsnap the sensor shield assembly from the machine.
A
3. Remove the sensor shield assembly.
Replacement Warning: When replacing the sensor shield assembly, ensure that the spring (A) is properly
aligned and the sensor shield assembly opens and closes properly.
Repair information
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Standard bin actuator assembly removal
1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)”
on page 4-106 or “Laser cover removal (model X658)” on page 4-104.
2. Disconnect the connection (A) from the standard bin actuator assembly.
3. Press the tab (B) to release the standard bin actuator assembly 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.
4-44 Service Manual
Sensor (toner density) removal
1. Remove the sensor shield assembly. See “Sensor shield assembly removal” on page 4-42.
2. Remove the two screws (A) securing the sensor (toner density) to the machine.
3. Remove the sensor (toner density).
4. Disconnect the connection (B) to the sensor (toner density).
Switch (media size) assembly removal
1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
2. Remove the six screws (A) securing the metal cover to the machine.
A
3. Remove the metal cover.
4. Remove the media tray.
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5. Gently place the machine on the left of right side.
6. Release the two hooks (B) securing the switch (media size) assembly to the machine.
B
C
7. Remove the switch (media size) assembly.
8. Disconnect the connection (C) from the switch (media size) assembly.
4-46 Service Manual
LVPS card assembly removal
WARNING: When replacing the LVPS card assembly, ensure that the voltage selection switch is set to the
proper setting, or damage will occur.
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36.
2. Remove the side cover, right. See “Side cover, right removal (models X651, X652/5535dn, X654,
and X656)” on page 4-122 or “Side cover, right removal (model X658)” on page 4-121.
3. Disconnect the connector (A) from the LVPS card assembly.
4. Remove the two screws (B) from the LVPS card assembly.
B
A
B
5. Gently pull the LVPS card assembly from the machine.
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6. Disconnect the connector (C) from the LVPS card assembly.
C
7. Remove the LVPS card assembly.
Replacement Warning: When replacing the LVPS card assembly, ensure that all connections are replaced.
Replacement Warning: When replacing the LVPS card assembly, ensure that the connector pins (D)
properly engage the system card.
Replacement Warning: When replacing the LVPS card assembly, ensure that the voltage selection switch
(E) is set to the proper setting, or damage will occur.
D
E
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Access door removal
1. Open the access door.
2. Gently detach the two hinges (A) of the access door from the machine.
A
3. Remove the access door.
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System card assembly removal
CAUTION
This product contains a lithium battery. THERE IS A RISK OF EXPLOSION IF THE BATTERY
IS REPLACED BY AN INCORRECT TYPE. Discard used batteries according to the battery
manufacturer’s instructions and local regulations.
Warning: When replacing any of the following components:
• Scanner interface card assembly
• System card assembly
• Scanner unit assembly
Only replace one component at a time. replace the required component and perform a POR before replacing a
second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never
replace two or more of the components listed above without a POR after installing each one or the printer will
be rendered inoperable.
Warning: These components 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.
1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123 or “Side cover, left removal (model X658)” on page 4-123.
2. Remove the six screws (A) securing the metal shield to the machine.
A
3. Slide the metal shield in the direction of the arrow.
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4. Remove the metal shield.
WARNING: When disconnecting all the electrical connections, ensure that the connectors and harnesses do
not become damaged.
5. Disconnect all connections from the system card assembly.
Note: There are two fine thread screws and four course thread screws securing the system card assembly to
the machine, ensure that these screws are properly reinstalled.
6. Remove the six screws (B) securing the system card assembly to the machine.
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WARNING: When removing the system card assembly from the machine, ensure that the LVPS assembly
connection (C) does not become damaged.
B
C
7. Remove the system card assembly.
8. Remove any remaining screws securing the system card assembly to the metal box.
9. Remove the system card assembly.
Replacement Warning: Ensure that all ground wires are properly replaced.
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.
4-52 Service Manual
Hard drive removal
1. Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123.
2. Loosen the two screws (A) securing the hard drive to the rear of the machine.
A
3. Remove the system card metal plate.
4. Gently detatch the hard drive from the system card.
Hard drive connector
5. Disconnect the connector from the system card.
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Hard drive cooling fan removal
1.
2.
3.
4.
5.
Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123.
Remove the system card metal plate.
Loosen the five screws securing the fan mounting bracket to the machine.
Remove the fan mounting bracket.
Remove the two screws (A) securing the hard drive cooling fan to the fan mounting bracket.
A
Connector
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.
4-54 Service Manual
Fax card assembly removal
1. Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123.
2. Remove the system card metal plate.
3. Loosen the two screws (A) securing the fax card assembly to the rear of the machine.
A
4. Gently detatch the fax card assembly from the machine.
Fax connector
5. Disconnection the connection from the system card.
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Transfer roll assembly removal
1. Open the operator panel door assembly.
2. Remove the print cartridge.
3. Gently unsnap the transfer roll assembly from the machine.
4. Remove the transfer roll assembly.
Replacement Warning: When replacing the transfer roll assembly, do not touch the foam surface.
4-56 Service Manual
Transfer roll bracket assembly, left removal
1. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-56.
2. Remove the inner deflector. See “Inner deflector removal” on page 4-17.
3. Remove the screw (A) securing the transfer roll bracket assembly, left to the machine.
4. Remove the transfer roll bracket assembly, left.
5. Remove the roll clamp (B) from the transfer roll bracket assembly, left.
6. Remove the bushing (C).
7. Remove the spring (D).
8. Remove the screw (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.
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3. Remove the screw (A) securing the transfer roll bracket assembly, right to the machine.
A
4. Remove the transfer roll bracket assembly, right.
4-58 Service Manual
Transfer deflector removal
1. Remove the transfer roll assembly. See “Transfer roll assembly removal” on page 4-56.
2. Gently unsnap the transfer deflector from the machine.
3. Remove the transfer deflector.
4. Remove the screw (A) securing the ground wire to the transfer deflector.
A
5. Remove the ground wire.
Replacement Warning: When replacing the transfer deflector, ensure that the ground wire is properly
replaced.
Repair information
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Redrive assembly removal
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-36.
2. Open the fuser access door.
3. Remove the two screws (A) securing the redrive assembly to the machine.
4. Press the two tabs (B) to release the redrive assembly to the machine.
While pressing the two tabs (B), pull the redrive assembly from the machine.
B
A
B
4-60 Service Manual
Rear
Left
Right
Front
ADF feed / pick roll assembly removal
1.
2.
3.
4.
Lift the ADF top door assembly.
Slide the ADF pick roll assembly to the front.
Lift the rear of the ADF pick roll assembly.
Remove the ADF pick roll assembly.
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ADF separator roll removal
1. Lift the ADF top door assembly.
2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61.
3. Remove the access cover.
4. Press tab (A), and slide the separator roll off the shaft.
A
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ADF separator torque limiter assembly removal
1. Lift the ADF top door assembly.
2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61.
3. Remove the access cover.
4. Press tab (A), and slide the separator roll off the shaft.
A
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5. Slide the ADF separator torque limiter assembly to the front, and remove.
ADF cover, front removal
1.
2.
3.
4.
Lift the ADF top door assembly.
Remove two screws (A) from the top of the front cover assembly.
Remove one screw (B) from the bottom of the ADF cover, front.
Release the bottom tabs (C) on the ADF cover, front.
A
C
B
5. Remove the ADF cover.
4-64 Service Manual
ADF cover, rear removal
1. Lift the ADF left door cover.
2. Remove two metal screws (A).
3. Remove the plastic screw (B) from the right side of the ADF cover, rear.
B
A
4. Remove the ADF cover, rear.
ADF document tray assembly removal
1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
2. Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65.
3. Remove the two metal 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.
Replacement note: You must adjust skew after reinstalling the document tray assembly. Go to “Adjusting
skew” on page 3-93.
Repair information
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ADF top door assembly removal
1.
2.
3.
4.
5.
6.
Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65.
Lift the ADF top door assembly.
Push down on the spring clips (A) on the left and right sides.
Remove the ADF left door links (B).
Unscrew the two hinge pins (C) on the left and right side.
A
C
B
C
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7. Pry out the front tabs (D).
D
8. Remove the ADF top door assembly.
ADF controller card removal
1. Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65.
2. Disconnect all cables attached to the controller card.
3. Remove the four screws (A) securing the ADF controller card.
4. Remove the ADF controller card.
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ADF platen cushion removal
1. Lift the ADF unit assembly.
2. Unfasten the velcro.
3. Remove the ADF platen cushion.
ADF lower door assembly removal
1. Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68.
2. Open the ADF bottom door by pressing the green tab (A) on the underside of the front of the ADF unit
assembly.
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.
B
A
C
5. Remove the hinge plate and pull the ADF lower door assembly and remove.
4-68 Service Manual
ADF duplex CCD scan glass assembly removal (X654, X656, and X658)
1.
2.
3.
4.
Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68.
Open the ADF lower door assembly.
Remove four screws (A) from the ADF duplex CCD scan glass assembly.
Pull up and release the two snaps (B) securing the ADF duplex CCD scan glass assembly.
B
A
5. Remove the ADF duplex CCD scan glass assembly.
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ADF duplex CCD assembly removal (X654, X656, and X658)
CAUTION: When you see this symbol, there is a danger from hazardous voltage in the area of the
product where you are working. Unplug the product before you begin, or use caution if the product
must receive power in order to perform the task.
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.
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
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4. Remove the two screws (C) securing the paper guide and remove.
5. Remove the three screws (D) from the underside of the ADF unit assembly securing the ADF duplex CCD
assembly to the ADF.
D
C
6. Carefully, remove the ADF duplex CCD assembly from the underside of the ADF unit assembly.
Replacement note: You must adjust skew after reinstalling the ADF duplex CCD assembly. Go to “Adjusting
skew” on page 3-93.
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ADF pinch roll assembly removal
1. Remove the ADF top door assembly. See “ADF top door assembly removal” on page 4-66.
2. Remove the two screws (A) on either side of the ADF pinch roll assembly.
A
3. Remove the ADF pinch roll assembly.
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ADF turn guide removal
1. Remove the ADF pinch roll assembly. See “ADF pinch roll assembly removal” on page 4-72.
2. Remove the ADF separator torque limiter assembly. See “ADF separator torque limiter assembly
removal” on page 4-63.
3. Remove the two screws (A) from the front side. Be sure to secure the ground strap by the upper turn guide
screw when reinstalling.
4. Using a flat-blade screwdriver, unfasten the hook securing the separator guide to the turn guide.
A
Note: Upon reassembly, reattach the hook by pressing with your fingers until it snaps into place.
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5. Pivot the turn guide out from the front side, giving room to dislodge the locating pins (B) from the rear.
A
B
6. Remove the ADF turn guide.
ADF media pinch pad assembly removal
1. Remove the ADF duplex CCD assembly. See “ADF duplex CCD assembly removal (X654, X656, and
X658)” 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.
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4. Remove the four screws (A) securing the ADF media pinch pad assembly.
A
5. Remove the ADF media pinch pad assembly.
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Sensor (ADF media exit) fan bracket assembly removal (X654, X656, and X658)
1.
2.
3.
4.
5.
6.
Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
Remove the ADF rear cover. See “ADF cover, rear removal” on page 4-65.
Open the ADF top door assembly.
Disconnect the ground strap, the fan (CN12) harness, and the media exit sensor (CN9) harness.
Remove the two screws (A) on the front and rear of the sensor (ADF media exit) fan bracket assembly.
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.
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ADF transport drive motor bracket assembly w/cable removal
1.
2.
3.
4.
5.
Remove the ADF cover, rear. See “ADF cover, rear removal” on page 4-65.
Remove the ADF transport drive motor bracket tension spring (A).
Remove the wires from the retaining clip (B) on top of the bracket.
Disconnect the ADF transport drive motor harness.
Remove the two screws (C) securing the ADF transport drive motor bracket assembly with cable to the
ADF feed motor bracket.
C
B
A
6. Slide the ADF transport drive 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
1. Remove the ADF transport motor bracket assembly with cable. See “ADF transport drive motor bracket
assembly w/cable removal” on page 4-77.
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
assembly.
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5. Remove the bushing from the pick roll feed shaft.
A
6. Remove the six screws (B) securing the ADF feed motor assembly to the ADF unit assembly.
B
7. Remove the ADF feed motor assembly to include two belts and cable.
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ADF pick roll position cam assembly removal
1. Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61.
3. Disengage the clip (A) on the shaft arm (B), securing it to the shaft.
A
B
4. Remove the two springs attached to the shaft arm (B).
B
5. Remove the three screws (C) securing the ADF pick roll position cam assembly bracket.
C
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.
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ADF solenoid assembly removal
1.
2.
3.
4.
Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
Remove the pick roll position cam assembly spring from the cam shaft lever.
Disconnect the solenoid wire harness.
Remove the two screws (A) securing the solenoid bracket assembly to the frame of the ADF unit
assembly.
5. Remove the ADF solenoid assembly.
Sensor (ADF top door interlock) removal
1. Remove the ADF cover, rear assembly. See “ADF cover, rear removal” on page 4-65.
2. Remove the feed motor bracket assembly. See “ADF feed drive motor assembly removal” on
page 4-77.
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.
B
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A
Sensor (ADF lower door interlock) removal
1.
2.
3.
4.
Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
Remove the ADF platen cushion. See “ADF platen cushion removal” on page 4-68.
Open the bottom door assembly.
Remove the sensor by squeezing the tabs (A) and removing it from the front of the ADF frame.
A
A
5. Disconnect the lower sensor (ADF lower door interlock) harness.
6. Remove the sensor (ADF lower door interlock).
Sensor (ADF 2nd scan) removal
1. Remove the ADF media pinch pad assembly. See “ADF media pinch pad assembly removal” on
page 4-74.
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
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4. Remove the sensor (ADF 2nd scan).
Sensor (ADF 1st scan) removal
1. Remove the ADF turn guide. See “ADF turn guide removal” on page 4-73.
2. Remove the screw (A) securing the sensor (ADF first scan) to its bracket.
A
3. Remove the sensor (ADF first scan).
4. Remove the sensor (ADF first scan) harness.
Sensor (ADF sheet through) removal
1. Remove the ADF turn guide. See “ADF turn guide removal” on page 4-73.
2. Remove the screw (A) securing the sensor (ADF sheet through) to its bracket.
A
3. Remove the sensor (ADF sheet through).
4. Remove the sensor (ADF sheet through) harness.
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Sensor (ADF document set) removal
1. Remove the ADF document tray assembly. See “ADF document tray assembly removal” on
page 4-65.
2. Remove the three screws (A) securing the separator guide to the ADF frame.
A
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.
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6. Remove the screw (C) securing the sensor (ADF document set) to the bracket.
B
C
Switch (ADF closed interlock) removal
1.
2.
3.
4.
Remove the ADF cover, rear assembly. See “ADF cover, rear removal” on page 4-65.
Open the ADF unit assembly.
Remove the ADF closed interlock harness from the switch.
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.
A
A
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ADF unit assembly removal (models X651, X652/5535dn, X654, and X656)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the scanner cover, left. See “Scanner cover, left removal (models X651, X652/5535dn,
X654, and X656)” on page 4-134.
Note: Models X651and X652/5535dn do not need the left scanner cover removed (no duplex ADF cable).
3.
4.
5.
6.
7.
Slide the left scanner cover to the rear, and remove.
Disconnect the CCD harness and ground strap from behind the left side scanner cover.
Disconnect the CCD harness and ground strap from behind the rear scanner cover.
Open the ADF.
Remove the two thumb screws (A) on either side of the ADF unit.
A
8. Slide ADF unit to the rear, lift up, and remove the ADF unit assembly.
Replacement note: You must adjust skew after reinstalling the ADF unit assembly. Go to “Adjusting skew”
on page 3-93.
ADF unit assembly removal (model X658)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the scanner support cover, left. See “Scanner support cover, left removal (model X658)” on
page 4-152.
3. Disconnect the CCD harness and ground strap from behind the scanner support cover, left.
4. Disconnect the CCD harness and ground strap from behind the rear scanner cover.
5. Open the ADF.
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6. Remove the two thumb screws (A) on both sides of the ADF unit.
A
7. Slide ADF unit to the rear, lift up, and remove the ADF unit assembly.
Replacement note: You must adjust skew after reinstalling the ADF unit assembly. Go to “Adjusting skew”
on page 3-93.
ADF left hinge removal
1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654,
and X656)” on page 4-85 or “ADF unit assembly removal (model X658)” on page 4-85.
2. Remove the ADF feed motor bracket assembly with cable. See “ADF feed drive motor assembly
removal” on page 4-77.
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3. Remove the screw (A).
A
4. Remove the ADF left hinge.
ADF right hinge removal
1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn,
X654, and X656)” on page 4-85 or “ADF unit assembly removal (model X658)” on page 4-85.
2. Remove the ADF cover, rear assembly. See “ADF cover, rear removal” on page 4-65.
3. Remove the four screws (A) securing the ADF right hinge to the ADF unit assembly.
A
4. Remove the ADF right hinge.
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Cover, left rear corner removal (model X658)
1. Remove the scanner support cover, left rear. See “Scanner support cover, left rear removal (model
X658)” on page 4-150.
2. Remove the two screws (A) securing the cover, left rear corner to the machine.
A
3. Slide the cover, left rear corner up and out.
Cover, right rear corner removal (model X658)
1. Remove the scanner support cover, right side rear. See “Scanner support cover, right rear removal
(model X658)” on page 4-127.
2. Open the rear door.
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3. Remove the two screws (A) securing the cover, right rear corner.
A
4. Lift and remove the cover, right rear corner.
Sensor (standard bin exit) actuator assembly removal
1. Open the upper rear door.
2. Remove the fuser access panel.
3. Remove the redrive assembly. See “Redrive assembly removal (models X651, X652/5535dn,
X654, and X656)” on page 4-103 or “Redrive assembly removal (model X658)” on page 4-103.
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4. Using a flat-blade screwdriver, press on the tab (A) securing the sensor (standard bin exit) actuator
assembly.
5. Position the sensor (standard bin exit) actuator assembly where the laser cover can be removed.
6. Remove the laser cover. See “Laser cover removal (model X658)” on page 4-104.
7. Remove the sensor (standard bin exit) actuator assembly.
Sensor (ADF media exit) bracket assembly removal (X651)
1.
2.
3.
4.
5.
Remove the ADF cover, front. See “ADF cover, front removal” on page 4-64.
Remove the ADF rear cover. See “ADF cover, rear removal” on page 4-65.
Open the ADF top door assembly.
Disconnect the ground strap, the fan (CN12) harness, and the media exit sensor (CN9) harness.
Remove the two screws (A) on the front and rear of the sensor (ADF media exit) fan bracket assembly.
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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.
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.
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Loosen the screw (A) on the carriage belt tensioner.
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3. Pull slack in the carriage belt, and retighten screw (A).
A
4. Slide the carriage belt out of the rear of the scanner CCD assembly.
5. Remove the rear CCD scanner shaft (B) from the flatbed frame, by lifting the left end of the shaft up and
remove through the left side.
B
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.
Replacement note: You must adjust skew after reinstalling the scanner CCD assembly. Go to “Adjusting
skew” on page 3-93.
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Scanner reference LED cable assembly removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Remove the screw (A) securing the scanner reference LED cable assembly to the flatbed frame.
A
3. Remove the scanner reference LED cable assembly.
4. Remove the wire harness from the scanner reference LED cable assembly.
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Scanner unit assembly removal (models X651, X652/5535dn, X654, and X656)
Warning: When replacing any of the following components:
• Scanner interface card assembly
• System card assembly
• Scanner unit assembly
Only replace one component at a time. replace the required component and perform a POR before replacing a
second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never
replace two or more of the components listed above without a POR after installing each one or the printer will
be rendered inoperable.
These components 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.
1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn, X654,
and X656)” on page 4-85.
2. Remove the scanner 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.
B
A
5. Remove the scanner cover, right. See “Scanner cover, right removal (models X651, X652/5535dn, X654,
and X656)” on page 4-136.
6. Remove the two plastic screws (C) securing the right side of the scanner unit assembly to the printer.
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7. Remove the screw (D) securing the ground strap to the frame of the scanner unit assembly.
D
C
8. Carefully slide the scanner unit assembly to the front, and lift up.
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Scanner unit assembly removal (model X658)
Warning: When replacing any of the following components:
• Scanner interface card assembly
• System card assembly
• Scanner unit assembly
Only replace one component at a time. replace the required component and perform a POR before replacing a
second component listed above. If this procedure is not followed, the printer will be rendered inoperable. Never
replace two or more of the components listed above without a POR after installing each one or the printer will
be rendered inoperable.
These components 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.
1.
2.
3.
4.
5.
6.
Remove the ADF unit assembly. See “ADF unit assembly removal (model X658)” on page 4-85.
Remove the side cover, left. See “Side cover, left removal (model X658)” on page 4-123.
Remove the scanner controller card cage cover.
Disconnect the CCD and ribbon cable harnesses.
Remove the three screws (A) from the right side of the scanner support.
Remove the three screws (B) from the left side of the scanner support.
B
A
7. Slide the flatbed scanner to the rear, and remove.
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MPF tray door assembly removal (models X651, X652/5535dn, X654, and X656)
1. Open the MPF tray door.
2. Carefully pry the left and right manual feeder tabs out of the slots in the manual feed tray.
3. Rotate the manual feeder vertical and pull straight up to remove the feeder.
4. Slide the MPF input tray towards the front, and remove two clips (A) securing the MPF door hinges.
A
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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).
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7. Continue to slide the MPF tray door assembly to the left, and remove.
MPF tray door assembly removal (model X658)
1. Open the MPF tray door assembly.
2. Remove the MPF media guide assembly. See “MPF media guide assembly removal (model X658)” on
page 4-108.
3. Remove the two retaining clips (A) from the hinges on the MPF tray door.
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4. Remove the left clip (B) securing the front door tension link.
B
A
5.
6.
7.
8.
Remove the left tension link.
Pull the right tension link from the hinge.
Slide the MPF tray door assembly to the left until all the bosses clear the hinges.
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.
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Fuser access assembly removal
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124.
2. Pull the fuser access assembly out to remove.
Output cover assembly removal (model X651, X652/5535dn, X654, and X656)
1. Open the door assembly, rear.
Note: If you do not have a short screwdriver, remove the scanner unit assembly. See “Scanner unit
assembly removal (models X651, X652/5535dn, X654, and X656)” on page 4-94.
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2. Remove the three screws (A) securing the output cover assembly to the machine.
A
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.
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Redrive assembly removal (model X658)
1.
2.
3.
4.
Remove the fuser access assembly. See “Fuser access assembly removal” on page 4-101.
Remove the two screws (A) securing the redrive assembly to the machine.
Remove the fuser wiper cover.
Release the left and right clips (B).
B
A
5. Remove the redrive assembly.
Redrive assembly removal (models X651, X652/5535dn, X654, and X656)
1. Remove the fuser access assembly. See “Fuser access assembly removal” on page 4-101.
2. Remove the two screws (A) securing the redrive assembly to the machine.
3. Remove the fuser wiper cover.
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4. Release the left and right clips (B).
B
A
5. Remove the redrive assembly.
Laser cover removal (model X658)
1. Remove the ADF unit assembly . See “ADF unit assembly removal (model X658)” on page 4-85.
2. Remove the scanner unit assembly. See “Scanner unit assembly removal (model X658)” on page 4-96.
3. Remove the scanner controller 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.
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5. Remove the five screws (A) on the left securing the laser cover.
A
6. Remove the four screws on the right (B) securing the laser cover.
B
7. Remove the sensor (ADF media exit) fan bracket assembly. See “Sensor (standard bin exit) actuator
assembly removal” on page 4-89.
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8. Remove the print cartridge cover. See “Print cartridge cover assembly removal (model X658)” on
page 4-120.
9. Remove the laser cover.
Laser cover removal (models X651, X652/5535dn, X654, and X656)
1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn,
X654, and X656)” on page 4-85.
2. Remove the scanner unit assembly. See “Scanner unit assembly removal (models X651,
X652/5535dn, X654, and X656)” on page 4-94.
3. Remove the scanner controller card. See “Scanner controller card assembly removal (models X651,
X652/5535dn, X654, and X656)” on page 4-132 or “Scanner controller card assembly removal
(model X658)” on page 4-129.
4. Remove the four screws (A) from the controller card cage.
A
5. Remove the controller card cage.
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6. Remove the three screws (B) on either side of the laser cover.
B
7. Remove the redrive assembly. See “Redrive assembly removal (models X651, X652/5535dn, X654,
and X656)” on page 4-103.
8. Remove the sensor (ADF media exit) bracket assembly. See “Sensor (ADF media exit) bracket
assembly removal (X651)” on page 4-90.
9. Open the front operator panel door.
10. Remove the laser cover.
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Standard output bin LED assembly removal (models X651, X652/5535dn, X654,
and X656)
1. Remove the scanner from the scanner support platform. See “Scanner support platform removal
(models X651, X652/5535dn, X654, and X656)” on page 4-141.
2. Remove screw (A) securing standard output bin LED assembly to the scanner support platform.
A
3. Remove the standard output bin LED assembly.
MPF media 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
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3. Push the spring on the right side down, and remove the MPF media guide assembly, by rotating the
assembly vertical and lift up.
Operator panel assembly removal (model X658)
1. Pull the operator panel door assembly forward, and remove.
2. 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.
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4.
5.
6.
7.
Remove the cover strip (C) from the operator panel assembly.
Remove the three screws (D) securing the operator panel assembly.
Slide the operator panel assembly to the left.
Rotate the operator panel assembly upside down, and remove the three screws (E).
C
D
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.
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Card reader assembly removal (model X658)
1. Remove the operator panel assembly. See “Operator panel assembly removal (model X658)” on
page 4-109.
2. Turn over the operator panel assembly.
3. Remove the 3 screws (A) from the back of the operator panel assembly.
4. Separate the lower panel (B) from the upper panel, and turn it over.
A
B
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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
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E
8. Disconnect the cable (F) from the card reader.
F
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USB cable removal (model X658)
1. Remove the operator panel assembly. See “Operator panel assembly removal (model X658)” on
page 4-109.
2. Turn over the operator panel assembly.
3. Remove the 3 screws (A) from the back of the operator panel assembly.
4. Separate the lower panel (B) from the upper panel
A
B
5. Turn the upper panel to face the inner part.
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6. Remove the two screws (C) securing the USB cable (D) to the upper panel.
7. Disconnect the USB Cable.
C
D
Operator panel door assembly removal (models X651, X652/5535dn, X654, and X656)
1. Remove the laser cover. See “Laser cover removal (models X651, X652/5535dn, X654, and X656)”
on page 4-106.
2. Remove the counter balance springs (A) on both sides.
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.
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5. Remove the pins (D) on both sides securing the links.
C
D
A
B
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6. Remove eight screws (E) securing the scanner controller cage cover to the cage. An X658 model is
represented in the graphic below, however, the card cage cover removal procedure is similar for all
models.
E
E
7. Remove the printer controller card cage cover.
8. Disconnect the USB cable and the cover closed interlock switch harness.
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9. Lift the operator panel door assembly out of the machine.
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Operator panel cover latch assembly removal (models X651, X652/5535dn, X654,
and X656)
1. Lift the operator panel cover assembly.
2. Remove the ten screws (A) securing the operator panel cover latch assembly to the operator panel cover
assembly.
3. Remove the operator panel cover latch assembly.
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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.
A
3. Remove the cartridge access door.
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Side cover, right removal (model X658)
1.
2.
3.
4.
Remove the cover, left rear corner. See “Cover, left rear corner removal (model X658)” on page 4-88.
Open the front door.
Open the cartridge access door.
Remove the screw (A), and pull the side cover, right up and out to remove.
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Side cover, right removal (models X651, X652/5535dn, X654, and X656)
1.
2.
3.
4.
5.
6.
7.
Remove the door assembly, rear assembly. See “Door assembly, rear removal” on page 4-124.
Remove the cover, rear lower. See “Cover, rear lower removal” on page 4-125.
Open the paper tray.
Open the MPF door.
Open the front door assembly.
Remove three screws (A) from the front.
Remove the screw (B) from the rear.
8. Firmly grasp the cover from the top, and pull out to remove.
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Side cover, left removal (model X658)
1. Remove the cover, left rear corner. See “Cover, left rear corner removal (model X658)” on page 4-88.
2. Open the cartridge access door.
3. Release the two tabs (A) in the front.
A
4. Remove the side cover, left.
Side cover, left removal (models X651, X652/5535dn, X654, and X656)
1.
2.
3.
4.
5.
Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124.
Remove the rear lower door. See “Cover, rear lower removal” on page 4-125.
Remove the paper tray.
Open the MPF door.
Open the cartridge access door.
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6. Remove the three screws (A) securing the side cover, left to the machine.
A
7. Remove the side cover, left by pulling out the tabs on the top and bottom and by pulling the cover out of its
rear hinges.
Door assembly, rear removal
1. 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.
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4. Remove the door assembly, rear.
Cover, rear lower removal
1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124.
2. Remove the two screws (A) on each side of the cover.
3. Open the cover, rear lower.
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4. Remove the remaining two screws (B).
A
B
5. Lift and remove the cover, rear lower.
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A
Scanner support cover, right rear removal (model X658)
1. Remove the four screws (A) securing the scanner support cover, right rear to the machine.
A
2. Remove the scanner support cover, right rear.
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Scanner support inner cover, right removal (model X658)
1. Remove the scanner support cover, right rear. See “Scanner support cover, right rear removal (model
X658)” on page 4-127.
2. Remove the four screws (A) securing the scanner support inner cover, right to the machine.
A
3. Pull the bottom out, and remove the scanner support inner cover, right.
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Scanner support cover, right removal (model X658)
1. Remove the scanner support inner cover, right. See “Scanner support inner cover, right removal
(model X658)” on page 4-128.
2. Remove the four (A) screws securing the scanner support cover, right to the machine.
3. Remove the scanner support cover, right.
Scanner controller card assembly removal (model X658)
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.
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3. Remove eight screws (A) securing the scanner controller cage cover to the cage.
A
A
4. Remove the scanner controller card cage cover.
5. Disconnect all the harnesses and ribbon cables.
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6. Remove the seven screws (B) securing the card to the cage.
7. Remove the scanner controller card.
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Scanner controller card assembly removal (models X651, X652/5535dn, X654,
and X656)
1. Remove the side cover, left. See “Side cover, left removal (models X651, X652/5535dn, X654, and
X656)” on page 4-123.
2. Remove eight screws (A) securing the scanner controller cage cover to the cage.
A
A
3. Remove the scanner controller card cage cover.
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4. Disconnect all the harnesses and ribbon cables.
5. Remove the seven screws (B) securing the card to the cage.
6. Remove the scanner controller card.
Scanner cover, rear removal
1. Remove the four screws (A) securing the scanner cover, rear to the scanner.
2. Pull out from the bottom, and remove the scanner cover, rear.
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Scanner cover, left removal (models X651, X652/5535dn, X654, and X656)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the metal screw (A) and plastic screw (B) securing the scanner cover, left to the scanner
assembly.
A
B
3. Slide the scanner cover, left to the rear, and remove.
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Scanner cover, left removal (model X658)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the metal screw (A) securing the scanner cover, left to the scanner assembly.
A
3. Slide the scanner cover, left to the rear, and remove.
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Scanner cover, right removal (models X651, X652/5535dn, X654, and X656)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the plastic screw (A) and metal screw (B) securing the scanner cover, right to the scanner.
3. Side the scanner cover, right to the rear, and remove.
Scanner cover, right removal (model X658)
1. Remove the scanner cover, rear. See “Scanner cover, right removal (model X658)” on page 4-136.
2. Remove the screw (A) 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.
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Scanner cover, front removal (models X651, X652/5535dn, X654, and X656)
1. Open the ADF cover.
2. Firmly grasp one side of the scanner cover, front.
3. Pull and remove the scanner cover, front.
Scanner cover, front removal (model X658)
1. Remove the scanner cover, right. See “Scanner cover, right removal (model X658)” on page 4-136.
2. Remove screw (A)
A
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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.
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Scanner platen glass cover assembly removal (model X658)
1.
2.
3.
4.
Remove the ADF unit assembly. See “ADF unit assembly removal (model X658)” on page 4-85.
Remove the scanner cover, left. See “Scanner cover, left removal (model X658)” on page 4-135.
Remove the scanner cover, right. See “Scanner cover, right removal (model X658)” on page 4-136.
Remove the scanner cover, front. See “Scanner cover, front removal (model X658)” on page 4-137.
Note: Remove the operator panel screw cover strip to access the 6th screw securing the platen glass cover
assembly.
Note: It is not necessary to remove the operator panel for platen glass removal.
5. Remove six screws (A) securing the scanner platen glass cover to the assembly.
6. Lift and remove the scanner platen glass cover assembly.
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Scanner platen glass cover assembly removal (models X651, X652/5535dn, X654,
and X656)
1. Remove the ADF unit assembly. See “ADF unit assembly removal (models X651, X652/5535dn,
X654, and X656)” on page 4-85.
2. Remove the scanner cover, front. See “Scanner cover, front removal (models X651, X652/5535dn,
X654, and X656)” on page 4-137.
3. Remove the scanner cover, right. See “Scanner cover, right removal (models X651, X652/5535dn,
X654, and X656)” on page 4-136.
4. Remove six screws (A) securing the scanner platen glass cover to the assembly.
A
5. Lift and remove the scanner platen glass cover assembly.
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Scanner support platform removal (models X651, X652/5535dn, X654, and X656)
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140.
2. Remove six screws (A) securing the scanner support platform to the scanner flatbed frame.
A
3. Remove two screws (B) securing the plastic cover to the scanner flatbed 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.
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6. Remove the two screws (D) securing the ground straps to the either side of the scanner frame.
Note: Remove the ground strap to prevent damage to the 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.
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Carriage belt tensioner assembly removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Remove the tensioner spring from the carriage belt tensioner. and remove the carriage belt from the
tensioner 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.
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Carriage drive motor assembly with cable removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Loosen the screw (A) on the carriage belt tensioner.
A
3.
4.
5.
6.
7.
Pull slack in the carriage belt and retighten screw (A).
Remove the clip (B) on the carriage output shaft.
Remove the retaining washer (C) and belt from the motor output shaft.
Remove the carriage drive motor harness (D).
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.
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8. Remove the four screws (F) securing the carriage drive motor assembly with cable to the flatbed frame.
F
F
9. Remove the carriage drive motor assembly with cable.
Carriage belt removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Loosen the screw (A) on the carriage belt tensioner.
A
3. Pull 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.
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6. Slide the carriage belt out of the rear side of the CCD carriage assembly.
4-146 Service Manual
Scanner / ADF duplex CCD exposure lamp removal
1. Remove the scanner CCD assembly or the ADF duplex CCD assembly. See “Scanner CCD assembly
removal” on page 4-91 or “ADF duplex CCD assembly removal (X654, X656, and X658)” on
page 4-70.
2. Remove the three screws (A) securing the scanner exposure lamp and wire harness.
3. Remove the lamp reflector (B) from the CCD assembly.
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.
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6. Remove the scanner exposure lamp wiring harness from the clips (D) on the CCD assembly.
7. Remove the scanner exposure lamp by lifting up on the rear end and pulling the lamp out of the grommet.
Scanner interface card assembly removal
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
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.
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Scanner cooling fan filter removal
1. Pry the tabs (A) securing the scanner cooling fan filter cover to the flatbed frame.
Scanner cooling fan removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Disconnect the cooling fan wiring harness from the scanner interface 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.
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Scanner support cover, left rear removal (model X658)
1. Remove the scanner cover, rear. See “Scanner cover, rear removal” on page 4-133.
2. Remove the two inner screws (A) and two screws (B) on the rear face securing the scanner support cover,
left rear to the machine.
B
A
3. Remove the scanner support cover, left rear.
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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.
A
3. Remove the scanner support cover, left front.
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Scanner support cover, left removal (model X658)
1. Remove the scanner support cover, left rear. See “Scanner support cover, left rear removal (model
X658)” on page 4-150.
2. Remove the scanner support cover, left front. See “Scanner support cover, left front removal (model
X658)” on page 4-151.
3. Remove the four screws (A) from the inside panel.
4. Remove the scanner support cover, left.
Scanner support inner cover, left removal (model X658)
1. Remove the scanner support cover, left rear. See “Scanner support cover, left rear removal (model
X658)” on page 4-150.
2. Remove the scanner support cover, left front. See “Scanner support cover, left front removal (model
X658)” on page 4-151.
3. Remove the scanner support cover, left. See “Scanner support cover, left removal (model X658)” on
page 4-152.
4. Remove the two screws (A) securing the scanner support inner cover, left.
5. Slide the scanner support inner cover, left to the front, and remove.
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Sensor (platen glass length) assembly removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Remove the two screws (A) securing the sensor (platen glass length) assembly to the scanner flatbed
frame.
3. Remove the screw (B) securing the sensor (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.
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Sensor (scanner HP) assembly w/bracket removal
1. Remove the scanner platen glass cover assembly. See “Scanner platen glass cover assembly removal
(models X651, X652/5535dn, X654, and X656)” on page 4-140 or “Scanner platen glass cover
assembly removal (model X658)” on page 4-139.
2. Remove screw (A) securing the HP sensor bracket to the flatbed frame.
A
3. Pull the bracket from the frame, and remove the sensor wire harness.
4. Remove the sensor (scanner HP) assembly with bracket.
LVPS cooling fan
1. Remove the LVPS card assembly. See “LVPS card assembly removal” on page 4-47.
2. Remove the four screws (A) securing the LVPS cooling fan.
A
3. Disconnect the connection from the LVPS cooling fan.
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4. Remove the LVPS cooling fan.
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Option removals
High capacity input tray
4-156 Service Manual
High capacity input tray (HCIT) media tray assembly removal
1. Open the HCIT media tray assembly until it reaches a stop.
2. Press the latch (A) down on the left side of the HCIT tray slide, and press the latch (B) up on the right side
of the HCIT tray slide.
B
A
3. Slide the HCIT media tray assembly out of the drawer.
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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
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A
3. Remove the HCIT tray cover, front.
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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
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2. Remove the HCIT cover, rear.
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High capacity input tray (HCIT) cover, right removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
Note: Before removing the HCIT right cover, first remove the right side anti-tip latch assembly. See “High
capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-165.
1. Remove the High capacity input tray (HCIT) cover, rear. See “High capacity input tray (HCIT) cover, rear
removal” on page 4-160.
2. Remove the six screws (A) securing the HCIT cover, right to the drawer.
3. Use a screwdriver to gently pry up on the tabs (B).
A
B
A
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A
4. Remove the HCIT cover, right.
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High capacity input tray (HCIT) cover, left removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
Note: Before removing the HCIT cover, left, first remove the left side anti-tip latch assembly. See “High
capacity input tray (HCIT) anti-tip latch assembly removal” on page 4-165.
1. Remove the HCIT cover, rear. See “High capacity input tray (HCIT) cover, rear removal” on
page 4-160.
2. Remove the six screws (A) securing the HCIT cover, left to the drawer.
3. Use a screwdriver to gently pry up on the tabs (B).
A
B
A
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4. Remove the HCIT cover, left.
High capacity input tray (HCIT) anti-tip latch assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
The left and right anti-tip latch assemblies are the same, and only one is in a package. The instructions below
are for removing the left latch; removing the right latch has similar instructions.
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1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
Note: The left side anti-tip assembly will come off when removing the HCIT cover, left.
4-166 Service Manual
High capacity input tray (HCIT) drawer slide assembly removal
The left and right drawer slide assemblies are the same, and only one is in a package. The instructions below
are for removing the left slide; removing the right slide has similar instructions.
1. Remove the HCIT media tray assembly. See “High capacity input tray (HCIT) media tray assembly
removal” on page 4-157.
2. Remove the three screws (A) securing the HCIT drawer slide to the frame of the drawer.
A
3. Remove the HCIT drawer slide.
High capacity input tray (HCIT) tray lift drive motor assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT cover, right. See “High capacity input tray (HCIT) cover, right removal” on
page 4-162.
2. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
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3. Disconnect the HCIT tray lift drive motor cable connector from the HCIT controller card assembly.
Note: Remove the cable from the restraint, and observe the routing for reinstallation.
4. Remove the eight screws (A) securing the HCIT tray lift drive motor assembly.
A
A
5. Remove the HCIT tray lift drive motor assembly.
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High capacity input tray (HCIT) controller card assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
2. Disconnect all connectors from the HCIT controller card assembly.
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3. Remove the three screws (A) securing the HCIT controller card assembly.
A
4. Remove the HCIT controller card assembly and the shield.
High capacity input tray (HCIT) media size actuator assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT controller card assembly. See “High capacity input tray (HCIT) controller card
assembly removal” on page 4-169.
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
B
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4. Snap loose the actuator switch (C) and remove.
C
5. Remove the four screws (D) securing the media size actuator (E) and the card mount option (F) to the
frame.
E
D
F
6. Remove the screw securing the media size actuator to the card mount option.
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7. Remove the media size actuator from the card mount option.
8. Remove the card mount option.
Sensor (HCIT tray raised HP) with cable assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
2. 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.
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A
5. Remove the sensor (HCIT tray raised HP).
Sensor (HCIT pass through) with cable removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
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2. Disconnect the sensor (HCIT pass through) from the HCIT controller card assembly.
Note: Remove the cable restraint, and observe the routing for reinstallation.
3. Release the hooks (A) securing the sensor (HCIT pass through) to the machine.
4. Remove the sensor (HCIT pass through) with cable from the top plate.
A
A
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High capacity input tray (HCIT) pick arm bracket assembly removal
Note: Carefully remove the base machine from the HCIT tray assembly before proceeding.
1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on page 4-164.
2. 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.
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4. Remove the five screws (A) securing the HCIT pick arm bracket assembly.
A
5. Remove the HCIT pick arm bracket assembly from the drawer by slightly lifting and removing it.
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High capacity input tray (HCIT) tray closed latch with spring removal
The left and right tray closed latches with springs are the same, and only one is in a package. The instructions
below are for removing the left latch; removing the right latch has similar instructions.
1. Remove the HCIT tray assembly. See “High capacity input tray (HCIT) media tray assembly removal”
on page 4-157.
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.
A
B
3. Remove the HCIT tray closed latch with spring.
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250-sheet media tray assembly removal
Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly.
250-sheet option drawer assembly removal
Remove the 250-sheet media tray assembly from the 250-sheet option drawer assembly.
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250-sheet pick arm bracket assembly removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Disconnect the two 250-sheet pick arm bracket assembly cable connectors from the 250-sheet controller
card assembly.
2. Detach the pick arm spring from the drawer.
3. Remove the three screws (A) securing the 250-sheet pick arm bracket assembly to the drawer.
A
4. Remove the 250-sheet pick arm bracket assembly.
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250-sheet media out actuator removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal”
on page 4-179.
2. Release the hook (A) securing the 250-sheet media out actuator to the 250-sheet pick arm bracket
assembly.
A
3. Remove the 250-sheet media out actuator from the drawer.
Anti-tip latch assembly removal
Note: Carefully remove the base machine from the input option 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, but removing the right latch is similar.
1. Remove the 250-sheet tray assembly. See “250-sheet media tray assembly removal” on page 4-178.
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.
A
3. Remove the anti-tip latch assembly.
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250-sheet frame assembly removal
Note: The 250-sheet frame assembly is not a FRU.
1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal”
on page 4-179.
2. Release the hooks securing the sensor (pass through) to the drawer.
3. 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.
Sensor (pass through) with cable removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal”
on page 4-179.
2. Release the hooks securing the sensor (pass through) to the drawer.
3. Remove the sensor (pass through) from the drawer.
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4. Remove the four screws (A) securing the 250-sheet frame assembly to the drawer.
5. Remove the 250-sheet frame assembly.
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6. Disconnect the sensor (pass through) cable connector from the 250-sheet controller card.
7. Remove the sensor (pass through) with cable.
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250-sheet controller card assembly removal
1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal”
on page 4-179.
2. Release the hooks securing the sensor (pass through) to the drawer.
3. Remove the sensor (pass through) from the drawer.
4. Remove the four screws (A) securing the 250-sheet frame assembly to the drawer.
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5. Remove the 250-sheet frame assembly.
6. Disconnect the three connectors from the 250-sheet controller card assembly.
7. Remove the three screws (B) securing the 250-sheet controller card assembly to the 250-sheet frame.
A
8. Remove the 250-sheet controller card assembly.
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Media size actuator removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Remove the 250-sheet controller card assembly. Go to “250-sheet controller card assembly removal”
on page 4-184.
2. Remove the screw (A) securing the media size actuator to the 250-sheet frame.
A
3. Remove the media size actuator.
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Media tray catch spring removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Remove the 250-sheet pick arm bracket assembly. See “250-sheet pick arm bracket assembly removal”
on page 4-179.
2. Release the hooks securing the sensor (pass through) to the drawer.
3. 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.
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6. Turn the drawer over so that you can access the media tray catch spring.
7. Release the media tray catch spring.
Tray roller catch assembly removal
Note: Carefully remove the base machine from the input option tray assembly before proceeding.
1. Remove the media tray catch spring. See “Media tray catch spring removal” on page 4-187.
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2. Remove the tray roller catch assembly from the drawer.
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550-sheet option tray assembly
4-190 Service Manual
550-sheet media tray assembly removal
Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly.
550-sheet option drawer assembly removal
Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly.
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550-sheet pick arm bracket assembly removal
1. Remove the 550-sheet media tray assembly. See “550-sheet media tray assembly removal” on
page 4-191.
2. Remove the two 550-sheet pick arm bracket assembly cable connectors (A) from the 550-sheet controller
card assembly.
3. Detach the 550-sheet bellcrank recoil spring (B) from the drawer.
4. Remove the four screws (C) securing the 550-sheet pick arm bracket assembly to the drawer.
A
5. Remove the 550-sheet pick arm bracket assembly.
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550-sheet bellcrank recoil spring removal
1. Remove the 550-sheet pick arm bracket assembly. See “550-sheet pick arm bracket assembly removal”
on page 4-192.
2. Remove the 550-sheet bellcrank recoil spring from the 550-sheet pick arm bracket assembly.
Media out actuator removal (models T652 and T654)
1. Remove the 550-sheet pick arm bracket assembly. See “550-sheet pick arm bracket assembly removal”
on page 4-192.
2. Release the hook (A) securing the media out actuator with spring to the 550-sheet pick arm bracket
assembly.
3. Detach the spring (B) from the media out actuator.
A
B
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Anti-tip latch assembly removal
The left and right anti-tip latch assemblies are the same, and only one is in a package. The instructions below
are for removing the left latch, but removing the right latch is similar.
1. Remove the 550-sheet media tray assembly. See “550-sheet media tray assembly removal” on
page 4-191.
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.
A
3. Remove the anti-tip latch assembly.
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550-sheet frame assembly removal
Note: The 550-sheet frame assembly is not a FRU.
1. Remove the 550-sheet pick arm bracket assembly. See “550-sheet pick arm bracket assembly removal”
on page 4-192.
2. Release the hooks securing the sensor (pass through) to the drawer.
3. Remove the sensor (pass through) from the drawer.
4. Remove the four screws (A) securing the 550-sheet frame assembly to the drawer.
A
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5. Remove the 550-sheet frame assembly.
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Upper interface cable assembly removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Disconnect the upper interface cable connector (A) from the 550-sheet controller card.
3. Release the two hooks (B) securing the options auto connect to the 550-sheet frame.
B
A
4. Remove the upper interface cable assembly.
Lower interface cable assembly removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Disconnect the lower interface cable connector (A) from the 550-sheet controller card.
3. Pinch the options auto connect (B) to separate the lower interface cable assembly from the 550-sheet
frame.
B
A
4. Remove the lower interface cable assembly.
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Sensor (pass through) with cable removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Disconnect the sensor (pass through) cable connector from the 550-sheet controller card.
3. Remove the sensor (pass through) with cable.
550-sheet controller card assembly removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Disconnect the three connectors from the 550-sheet controller card assembly.
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3. Remove the three screws (A) securing the 550-sheet controller card assembly to the 550-sheet frame.
A
4. Remove the 550-sheet controller card assembly.
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Media size actuator removal
1. Remove the 550-sheet controller card assembly. See “550-sheet controller card assembly removal” on
page 4-198.
2. Remove the screw (A) securing the media size actuator to the 550-sheet frame.
A
3. Remove the media size actuator.
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550-sheet option drive shaft with spring removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Pinch the two hooks (A) on the cap, and detach it from the 550-sheet frame.
3. Pull the drive roll gear (B), the shaft with spring (C), and the bevel out through the opening.
A
A
B
C
A
4. Remove the 550-sheet option drive shaft with spring.
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Media tray catch spring removal
1. Remove the 550-sheet frame assembly. See “550-sheet frame assembly removal” on page 4-195.
2. Turn the drawer over so that you can access the media tray catch spring.
3. Release the media tray catch spring.
Media tray roller catch assembly removal
1. Remove the media tray catch spring. See “Media tray catch spring removal” on page 4-202.
2. Remove the tray roller catch assembly from the drawer.
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MFP stapler assembly rear door assembly removal
1. Open the rear door assembly.
2. Force the left hinge out of the slot by pushing the door to the right.
3. Once the left hinge has been disengaged, pull the right hinge out.
4. 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.
A
2. Pull out on the front side of the right cover to disengage the tabs.
3. Remove the right cover.
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MFP stapler assembly left cover removal
1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover.
A
2. Pull out on the front side of the left cover to disengage the tabs.
3. Remove the left cover.
MFP stapler assembly top cover removal
1. Remove the left and right cover. See “MFP stapler assembly left cover removal” on page 4-204 and
“MFP stapler assembly right cover removal” on page 4-203.
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2. Remove the screw (A) on each side of the top cover.
A
3. Pull up and toward the front to remove the top cover.
MFP stapler assembly handle cover removal
1. Remove the left and right cover. See “MFP stapler assembly left cover removal” on page 4-204 and
“MFP stapler assembly right cover removal” on page 4-203.
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4-205
2. Remove the two screws (A) on each side of the.
A
A
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
4-206 Service Manual
2. Remove the standard output bin LED. See “MFP stapler assembly standard output bin LED and LED
clear lens removal” on page 4-208.
3. Remove the sensor (finisher media bin present). See “MFP stapler assembly sensor (finisher media bin
present) removal” on page 4-208.
4. Remove the LED sensor cover.
Repair information
4-207
MFP stapler assembly sensor (finisher media bin present) removal
1. Remove the LED sensor cover. See “MFP stapler assembly LED sensor cover removal” on
page 4-206.
2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover.
A
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
1. Remove the LED sensor cover. See “MFP stapler assembly LED sensor cover removal” on
page 4-206.
4-208 Service Manual
2. Remove the two screws (A) securing the LED to the cover.
A
3. Remove the LED and disconnect the harness.
4. Remove the LED clear lens.
MFP stapler assembly tamper drive belt removal
1. Remove the tamper recoil spring. See “MFP stapler assembly tamper drive belt removal” on
page 4-209.
2. Pull the belt out the tamper belt holder and remove the belt from the pulley.
Repair information
4-209
MFP stapler assembly tamper drive motor assembly removal
1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204.
2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley.
3. Disconnect the tamper driver motor harness from the controller card.
4. Remove the two screws (A) securing the tamper drive motor assembly to the tamper frame.
A
5. Remove the tamper drive motor assembly.
MFP stapler assembly media stack flap and media stack flap actuator removal
1. Remove the handle cover. See “MFP stapler assembly handle cover removal” on page 4-205.
2. Release the locking tab and slide the media stack flap actuator to the right and remove.
4-210 Service Manual
Repair information
4-211
MFP stapler assembly stapler unit assembly removal
1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203.
2. Remove the four cable harnesses attached to the stapler unit assembly.
3. Remove the three screws (A) securing the stapler unit assembly.
A
4. Remove the stapler unit assembly.
4-212 Service Manual
Stapler/stacker controller card assembly removal
1. Remove the left left cover. See “MFP stapler assembly left cover removal” on page 4-204.
2. Disconnect all harnesses to the controller card.
3. Remove the three screws (A) securing the stapler/stacker controller card assembly.
A
4. Remove the stapler/stacker controller card assembly.
MFP stapler assembly paddle drive motor assembly removal
1. Remove the left left cover. See “MFP stapler assembly left cover removal” on page 4-204.
2. Disconnect the paddle motor harness from the controller card.
3. Remove the cable from the harness clip.
Repair information
4-213
4. Remove the two screws (A) securing the two paddle drive motor assemblies.
A
5. Remove the paddle drive motor assembly.
4-214 Service Manual
MFP stapler assembly sensor (media stack) removal
1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204.
2. Disconnect the harness to the sensor (media stack).
3. Using your fingers, pinch tab (A) securing the sensor (media stack) and remove.
A
MFP stapler assembly sensor (paddle HP) removal
1. Remove the left cover. See “MFP stapler assembly left cover removal” on page 4-204.
2. Disconnect the harness to the sensor (paddle home position).
Repair information
4-215
3. Using your fingers, pinch tab (A) securing the sensor (paddle home position) and remove.
A
MFP stapler assembly sensor (stapler access door interlock) removal
1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203.
2. Disconnect the harness to the sensor (stapler access door interlock).
3. Using your fingers, pinch tab (A) securing the sensor (stapler access door interlock) and remove.
A
4-216 Service Manual
MFP stapler assembly sensor (tamper HP left and right) removal
1. Remove the top cover. See “MFP stapler assembly top cover removal” on page 4-204.
2. Disconnect the harness to the sensor (tamper HP left and right).
3. Using your fingers, pinch the tabs (A) securing the staple finisher sensor (tamper HP left and right) and
remove.
A
MFP stapler assembly sensor (bin full send) removal
1. Remove the stapler/stacker controller card assembly. See “Stapler/stacker controller card assembly
removal” on page 4-213.
Repair information
4-217
2. Remove the two screws (A) securing the staple finisher sensor (bin full send).
A
3. Disconnect the harness and remove.
MFP stapler assembly sensor (bin full receive) removal
1. Remove the right cover. See “MFP stapler assembly right cover removal” on page 4-203.
2. Remove the two screws (A) securing the sensor (bin full receive).
A
3. Disconnect the harness and remove.
4-218 Service Manual
MFP stapler assembly sensor (media in stapler) removal
1. Remove the stapler unit assembly from the . See “MFP stapler assembly stapler unit assembly
removal” on page 4-212.
2. Using a flat-blade screwdriver, release the tabs (A) securing the sensor.
A
3. Using needlenose pliers, carefully grip the sensor and pull it out and disconnect the harness.
Replacement Notes: Using needlenose pliers, place the rear most tab in the sensor bracket first. Then push
on the rear face of the sensor until the other two tabs snap into place.
Repair information
4-219
MFP stapler assembly sensor (deflector HP) removal
1. Remove the left cover. See “MFP stapler assembly left cover removal” on page 4-204.
2. Disconnect the harness to the sensor (deflector HP).
3. Release the tabs (A) securing the sensor to the unit.
A
Note: The tabs may be difficult to access. The use of a spring hook or flat-blade screwdriver may be
necessary to release the tabs.
4-220 Service Manual
4-bin mailbox assembly left cover removal
1. Place the 4-bin mailbox assembly on its side.
2. Remove the two screws (A) on the underside of the 4-bin mailbox assembly securing the left cover.
A
3. Using your finger, pull up on the top surface of the left cover while simultaneously pulling out, and remove.
4-bin mailbox assembly controller card assembly removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. Disconnect all harnesses from the controller card.
Note: Label each deflector gate solenoid cable for correct replacement upon installation.
Repair information
4-221
3. Remove the two screws (A) securing the controller card to the 4-bin mailbox assembly and remove.
4-bin mailbox assembly sensor (media bin full) removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. Disconnect the harness to the sensor (media bin full).
4-222 Service Manual
3. Pinch the tabs securing the sensor (media bin full) to the media tray and remove.
4-bin mailbox assembly sensor (deflector gate HP) removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. 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 left rear inner 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).
Repair information
4-223
4-bin mailbox assembly rear door assembly removal
1. Open the rear door.
2. Gently spread each side of the 4-bin mailbox assembly until the rear door hinge is free to be removed.
3. Remove the rear door assembly.
4-224 Service Manual
4-bin mailbox assembly right cover removal
1. Place the 4-bin mailbox assembly on its side.
2. Remove the two screws (A) from the bottom side of the right cover securing cover in place.
A
A
3. Using your fingers, pull up on the top of the right cover and pull out simultaneously to remove.
4-bin mailbox assembly LED card assembly removal
1. Remove the 4-bin mailbox assembly right cover. See “4-bin mailbox assembly right cover removal” on
page 4-225.
2. Disconnect the 3 wire harnesses attached to the LED card assembly.
Repair information
4-225
3. Remove the three screws (A) securing the LED card assembly to the 4-bin mailbox assembly.
A
4. Remove the 4-bin mailbox assembly LED card assembly.
4-bin mailbox assembly top cover removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. Remove the right cover. See “4-bin mailbox assembly right cover removal” on page 4-225.
3. Remove the four screws (A) on each side of the top cover securing it to the 4-bin mailbox assembly.
A
4-226 Service Manual
A
4. Slide the top cover towards the rear and remove.
4-bin mailbox assembly deflector gate solenoid removal
1. Remove the 4-bin mailbox assembly top cover. See “4-bin mailbox assembly top cover removal” on
page 4-226.
2. Remove the screw (A) securing the deflector gate solenoid to the 4-bin mailbox assembly.
A
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.
Repair information
4-227
4-bin mailbox assembly transport solenoid removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. Remove the left rear inner cover.
3. Disconnect the transport solenoid cable from the controller card.
4. Remove the screw (A) securing the transport solenoid to the 4-bin mailbox assembly.
A
5. Remove the transport solenoid and pull the cable through the left side frame.
4-228 Service Manual
4-bin mailbox assembly spring removal
1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door
assembly removal” on page 4-224.
2. Using a spring hook or needlenose pliers, remove the spring off the hooks.
Repair information
4-229
4-bin mailbox assembly deflector gate (bin 1 through 3) removal
1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door
assembly removal” on page 4-224.
2. Remove the 4-bin mailbox assembly right rear inner cover.
3. Remove the 4-bin mailbox assembly spring. See “4-bin mailbox assembly spring removal” on
page 4-229.
4. Grasp the deflector gate and pull it out of its socket on each side. Carefully remove the diverter from the
machine.
4-230 Service Manual
4-bin mailbox assembly deflector gate (bin 4) removal
1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door
assembly removal” on page 4-224.
2. Grasp the 4th bin deflector gate and pull out on either side.
Repair information
4-231
4-bin mailbox assembly sensor (pass through) removal
Note: The sensor (pass through) is the lower rear sensor. The rear upper sensor is the sensor (mailbox
empty).
1. Open the rear door.
2. Lift the deflector gate above the sensor (pass through) and using a flat-blade screwdriver, release the tabs
securing the sensor (pass through) to the 4-bin mailbox assembly.
3. Remove the 4-bin mailbox left cover. See “4-bin mailbox assembly left cover removal” on page 4-221.
4. Disconnect the sensor (pass through) harness from the controller board.
4-232 Service Manual
4-bin mailbox assembly sensor (mailbox empty) removal
Note: The sensor (pass through) is the lower rear sensor. The rear upper sensor is the sensor (mailbox
empty).
1. Open the rear door.
2. Lift the deflector gate above the sensor (mailbox empty) and using a flat-blade screwdriver, release the
tabs securing the sensor (mailbox empty) to the 4-bin mailbox assembly.
3. Remove the 4-bin mailbox left cover. See “4-bin mailbox assembly left cover removal” on page 4-221.
4. Disconnect the sensor (mailbox empty) harness from the controller board.
Repair information
4-233
4-bin mailbox assembly standard output bin LED removal
1. Remove the three screws (A) on the underside of bin 1 securing the output bin LED bracket.
A
2. Pull the output bin LED bracket out from the underside of bin 1 and disconnect the LED harness.
4-234 Service Manual
3. Remove the two screws (B) securing the output bin LED to the bracket and remove the output bin LED.
B
Repair information
4-235
4-bin mailbox assembly LED clear lens removal
1. Remove the 4-bin mailbox standard output bin LED. See “4-bin mailbox assembly sensor (mailbox
empty) removal” on page 4-233.
2. Remove the output bin LED clear lens from the output bin LED bracket.
4-bin mailbox assembly media bin full actuator removal
1. Remove the 4-bin mailbox assembly left cover. See “4-bin mailbox assembly left cover removal” on
page 4-221.
2. Pry the front hinge of the media bin full actuator towards the rear until the front boss is released from its
socket.
4-236 Service Manual
3. Pull the media bin full actuator toward the front and out of 4-bin mailbox assembly.
Offset stacker rear door assembly removal
1. Open the rear door assembly.
2. Force the left hinge out of the slot by pushing the door to the right.
3. 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.
A
2. Pull out on the front side of the right cover to disengage the tabs.
3. Remove the offset stacker right cover.
Repair information
4-237
Offset stacker left cover removal
1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover.
A
2. Pull out on the front side of the left cover to disengage the tabs.
3. Remove the offset stacker left cover.
Offset stacker top cover removal
1. Remove the left and right cover. See “Offset stacker left cover removal” on page 4-238 and “Offset
stacker right cover removal” on page 4-237.
4-238 Service Manual
2. Remove the screw (A) on each side of the top cover.
A
3. Pull up and toward the front to remove the offset stacker top cover.
Offset stacker handle cover removal
1. Remove the left and right cover. See “Offset stacker left cover removal” on page 4-238 and “Offset
stacker right cover removal” on page 4-237.
Repair information
4-239
2. Remove the two screws (A) on each side of the offset stacker.
A
A
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
4-240 Service Manual
2. Remove the offset stacker standard output bin LED. See “Offset stacker standard output bin LED and
LED clear lens removal” on page 4-242.
3. Remove the sensor (finisher media bin present). See “Offset stacker sensor (finisher media bin
present) removal” on page 4-242.
4. Remove the LED sensor cover.
Repair information
4-241
Offset stacker sensor (finisher media bin present) removal
1. Remove the offset stacker LED sensor cover. See “Offset stacker LED sensor cover removal” on
page 4-240.
2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover.
A
3. Remove 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
1. Remove the offset stacker LED sensor cover. See “Offset stacker LED sensor cover removal” on
page 4-240.
4-242 Service Manual
2. Remove the two screws (A) securing the LED to the cover.
A
3. Remove the LED and disconnect the harness.
4. Remove the LED clear lens.
Offset stacker tamper drive belt removal
1. Remove the offset stacker tamper recoil spring. See “Offset stacker tamper drive belt removal” on
page 4-243.
2. Pull the belt out the tamper belt holder and remove the belt from the pulley.
Repair information
4-243
Offset stacker tamper drive motor assembly removal
1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238.
2. Pull slack in the tamper drive belt and remove the belt from the tamper drive belt pulley.
3. Disconnect the tamper driver motor harness from the controller card.
4. Remove the two screws (A) securing the tamper drive motor assembly to the tamper frame.
A
5. Remove the tamper drive motor assembly.
Offset stacker media stack flap and media stack flap actuator removal
1. Remove the offset stacker handle cover. See “Offset stacker handle cover removal” on page 4-239.
2. Release the locking tab and slide the media stack flap actuator to the right and remove..
4-244 Service Manual
Repair information
4-245
Stapler/stacker controller card assembly removal
1. Remove the left left cover. See “Offset stacker left cover removal” on page 4-238.
2. Disconnect all harnesses to the controller card.
3. Remove the three screws (A) securing the stapler/stacker controller card assembly.
A
4. Remove the stapler/stacker controller card assembly.
Offset stacker paddle drive motor assembly removal
1. Remove the left left cover. See “Offset stacker left cover removal” on page 4-238.
2. Disconnect the paddle motor harness from the controller card.
3. Remove the cable from the harness clip.
4-246 Service Manual
4. Remove the two screws (A) securing the two paddle drive motor assemblies.
A
5. Remove the paddle drive motor assembly.
Offset stacker sensor (media stack) removal
1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238.
2. Disconnect the harness to the sensor (media stack).
Repair information
4-247
3. Using your fingers, pinch tab (A) securing the offset stacker sensor (media stack) and remove.
A
Offset stacker sensor (paddle HP) removal
1. Remove the offset stacker left cover. See “Offset stacker left cover removal” on page 4-238.
2. Disconnect the harness to the offset stacker sensor (paddle home position).
3. Using your fingers, pinch tab (A) securing the offset stacker sensor (paddle home position) and remove.
A
4-248 Service Manual
Offset stacker sensor (tamper HP left and right) removal
1. Remove the offset stacker top cover. See “Offset stacker top cover removal” on page 4-238.
2. Disconnect the harness to the offset stacker sensor (tamper HP left and right).
3. Using your fingers, pinch the tabs securing the staple finisher sensor (tamper HP left and right) and remove.
A
Offset stacker sensor (bin full send) removal
1. Remove the stapler/stacker controller card assembly. See “Stapler/stacker controller card assembly
removal” on page 4-246.
Repair information
4-249
2. Remove the two screws (A) securing the staple finisher sensor (bin full send).
A
3. Disconnect the harness and remove.
Offset stacker sensor (bin full receive) removal
1. Remove the offset stacker right cover. See “Offset stacker right cover removal” on page 4-237.
2. Remove the two screws (A) securing the sensor (bin full receive).
A
3. Disconnect the harness and remove.
4-250 Service Manual
Offset stacker sensor (deflector HP) removal
1. Remove the offset stacker left cover. See “Offset stacker left cover removal” on page 4-238.
2. Disconnect the harness to the sensor (deflector HP).
3. Release the tabs securing the sensor to the offset stacker.
Note: The tabs may be difficult to access. The use of a spring hook or flat-blade screwdriver may be
necessary to release the tabs.
Repair information
4-251
4-252 Service Manual
5. Connector locations
Locations
Sensors–ADF
Sensor (ADF media length)
Sensor (ADF media width)
Sensor (Media exit)
Sensor (ADF document set)
Sensor (ADF lower
door interlock)
ADF pick solenoid
Switch (ADF
closed interlock)
Sensor (ADF top
door interlock)
Sensor (ADF rear registration)
Sensor (ADF front registration)
Sensor (ADF sheet through)
Sensors–Flatbed
Connector locations
5-1
5-2
Service Manual
6. Preventive maintenance
This chapter describes procedures for printer preventive maintenance. Follow these recommendations to help
prevent problems and maintain optimum performance.
Safety inspection guide
The purpose of this inspection guide is to aid you in identifying unsafe conditions.
If any unsafe conditions exist, find out how serious the hazard could be and if you can continue before you
correct the hazard.
Check the following items:
• Damaged, missing, or altered parts, especially in the area of the On/Off switch and the power supply
• Damaged, missing, or altered covers, especially in the area of the top cover and the power supply cover
• Possible safety exposure from any non-Dell attachments
Lubrication specifications
Lubricate only when parts are replaced or as needed, not on a scheduled basis. Use of lubricants other than
those specified can cause premature failure. Some unauthorized lubricants 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 maintenance part expected life
Description
Part
number
Expected
part life
Charge roll assembly with tool
40X5852
300K
Transfer roll assembly with tool
40X1886
300K
Pick roll assembly (2)
40X4308
300K
Printer maintenance kit (100 V type 1 fuser)
40X4723
300K
Printer maintenance kit (110 V type 1 fuser)
40X4724
300K
Printer maintenance kit (220 V type 1 fuser)
40X4765
300K
Printer maintenance kit (100 V type 2 fuser)
40X4766
150K
Printer maintenance kit (110 V type 2 fuser)
40X4767
150K
Printer maintenance kit (220 V type 2 fuser)
40X4768
150K
ADF feed / pick roll assembly
40X4540
120K
ADF separator roll and guide
40X4605
120K
Preventive maintenance
6-1
Scheduled maintenance
Maintenance kit
The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval. It is
necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain
the print quality and reliability of the printer. The parts are available as a maintenance kit with the following part
numbers:
Maintenance kits
Part number
Maintenance
Interval
Printer maintenance kit (100V)
40X4723
300K
Printer maintenance kit (110V)
40X4724
300K
Description
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:
40X4769
120K
• ADF feed/pick roll assembly
• ADF separator roll and guide
After replacing the kit, the maintenance count must be reset to zero to clear the “80 Scheduled Maintenance”
message. See “Reset Maintenance Counter” on page 3-29.
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.
6-2 Service Manual
Cleaning the scanner glass
Clean the scanner glass if you encounter print quality problems, such as streaks on copied or scanned images.
1. Slightly dampen a soft, lint-free cloth or paper towel with 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.
1
2
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.
Preventive maintenance
6-3
9. Close the scanner cover.
Note: Dell recommends the use of Klear Screen cleaner for the scanner glass, LCD screen, and operator
panel buttons. This can be ordered from www.KlearScreen.com or by calling 1-800-505=5327. Order kit(s) KSSP12 or KS-SP50.
Warning: Dell does not recommend the use of any alcohol based solution on the operator panel buttons
or the LCD screen as cosmetic damage to those assemblies may result.
6-4 Service Manual
7. Parts catalog
How to use this parts catalog
The following legend is used in the parts catalog:
Asmindex
Part
number
Units/mach
- OR Units/option
Units/
FRU
Description
• 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.
• Part number: Identifies the unique number that identifies this FRU.
• Units/mach: Refers to the number of units actually used in the base machine or product.
• Units/option: Refers to the number of units in a particular option. It does not include the rest of the base
machine.
• Units/FRU: Refers to the number of units packaged together and identified by the part number.
• NS: (Not shown) in the Asm-Index column indicates that the part is procurable but is not pictured in the
illustration.
• PP: (Parts Packet) in the parts description column indicates the part is contained in a parts packet.
• Model information used in the parts catalog:
Machine
type
Description
AIO
Simplex
ADF
Duplex
ADF
Duplex
printer
7462-031
X651de
x
x
x
7462-035
X652de/
5535dn
x
x
x
7462-0A1
X654de
x
x
x
7462-0A5
X656dte
x
x
x
7462-231
X654de
x
x
x
7462-232
X654de
x
x
x
7462-235
X656dte
x
x
x
7462-236
X656dte
x
x
x
7462-2A1
X654de
x
x
x
7462-2A2
X654de
x
x
x
7462-2A5
X656dte
x
x
x
7462-2A6
X656dte
x
x
x
7462-432
X658de
x
x
x
7462-436
X658de
x
x
x
7462-4A2
X658de
x
x
x
7462-4A6
X658de
x
x
x
Modem
Hard drive
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
x
Parts catalog
7-1
Assembly 1: Covers (X651, X652/5535dn, X654, and X656)
7-2 Service Manual
Assembly 1: Covers (X651, X652/5535dn, X654, and X656)
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X2169
1
1
Scanner cover plug, rear (X651)
2
40X4506
1
1
Scanner cover, rear
3
40X4508
1
1
Scanner cover, right (X651, X652, X654, and X656)
4
40X4509
1
1
Scanner support platform (X651, X652, X654, and X656)
5
40X1919
1
1
Output cover assembly (X651, X652, X654, and X656)
6
40X4331
1
1
Door assembly, rear
7
40X4470
1
1
Output bail
8
40X4417
1
1
Fuser wiper cover
9
40X1918
1
1
Laser cover assembly, 550 sheet(X651, X652, X654, and X656)
10
40X4335
1
1
Cover assembly, rear lower
11
40X4629
1
1
Connection bezel assembly, rear
12
40X1917
1
1
Side cover, right (X651, X652, X654, and X656)
13
40X1972
1
1
Inner cover, right (X651, X652, X654, and X656)
14
40X2045
1
1
Operator panel cable assembly (X651, X652, X654, and X656)
15
40X2089
1
1
MPF tray door assembly (X651, X652, X654, and X656)
16
40X2077
2
1
Counter balance spring (X651, X652, X654, and X656)
17
40X2078
2
1
Spring connector (X651, X652, X654, and X656)
18
40X4631
1
1
Operator panel door latch assembly (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
40X1971
1
1
Inner cover, left (X651, X652, X654, and X656)
23
40X1916
1
1
Side cover, left (X651, X652, X654, and X656)
24
40X4481
1
1
Access door (X651, X652, X654, and X656)
25
40X1973
1
1
Media support (X651, X652, X654, and X656)
26
40X4598
1
1
Card reader cover assembly (X651, X652, X654, and X656)
27
40X4604
1
1
Card reader assembly (5125 contact/HID)
27
40X4602
1
1
Card reader assembly (3121 contact)
27
40X4603
1
1
Card reader assembly (5121 contact/RFID)
28
40X2638
1
1
Standard output bin LED assembly (X651, X652, X654, and X656)
29
40X2643
1
1
Standard output bin LED cable assembly
30
40X4601
1
1
Card reader cable assembly (X651, X652, X654, and X656)
31
40X4505
1
1
Scanner cover, front (X651, X652, X654, and X656)
32
40X4507
1
1
Scanner cover, left (X651, X652, X654, and X656)
Parts catalog
7-3
Assembly 2: Covers 1 (X658)
2
3
1
21
4
20
5
20
6
19
7
18
10
17
15
16
14
9
10
12
13
7-4 Service Manual
11
8
Assembly 2: Covers 1 (X658)
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X1970
1
1
Laser cover assembly, 550 sheet (X658)
2
40X4480
1
1
Output cover assembly (X658)
3
40X4331
1
1
Door assembly, rear
4
40X4470
1
1
Output bail
5
40X4335
1
1
Cover assembly, rear lower
6
40X4477
1
1
Corner cover, left rear (X658)
7
40X4479
1
1
Corner cover, right rear (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 (X658)
18
40X4475
1
1
Access door (X658)
19
40X1977
1
1
Print cartridge cover assembly (X658)
20
40X4489
2
1
Print cartridge recoil spring (X658)
21
40X2017
1
1
Media support (X658)
Parts catalog
7-5
Assembly 3: Covers 2 (X658)
7-6 Service Manual
Assembly 3: Covers 2 (X658)
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X4510
1
1
Scanner cover, rear (X658)
2
40X4511
1
1
Scanner cover, right (X658)
3
40X4513
1
1
Scanner cover, front (X658)
4
40X4516
1
1
Scanner support cover, left rear (X658)
5
40X4520
1
1
Scanner support inner cover, right (X658)
6
40X4517
1
1
Scanner support cover, right (X658)
7
40X4518
1
1
Scanner support cover, right rear (X658)
8
40X1974
1
1
Stapler access cover (X658)
9
40X4514
1
1
Scanner support cover, left front (X658)
10
40X4515
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)
17
40X4603
1
1
Card reader assembly (5121 contact/RFID)
17
40X4604
1
1
Card reader assembly (5125 contact/HID)
18
40X4491
1
1
Operator panel bezel (X658)
19
40X4492
1
1
Operator panel cable assembly (X658)
20
40X4500
1
1‘
USB cable assembly (X658)
21
40X4600
1
1
Card reader cable assembly (X658)
22
40X4512
1
1
Scanner cover, left (X658)
Parts catalog
7-7
Assembly 4: Media path and ducts
7-8 Service Manual
Assembly 4: Media path and ducts
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4384
1
1
EP cooling fan duct
2
40X1868
2
1
Print cartridge clamp assembly
3
40X4390
4
1
Machine pad
4
40X1869
1
1
Transfer deflector with static 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 (X651, X652, X654, and X656)
14
40X4318
1
1
Fuser access door assembly
Parts catalog
7-9
Assembly 5: Pick arm and media tray assemblies
7-10 Service Manual
Assembly 5: Pick arm and media tray assemblies
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4459
1
1
MPF lift plate assembly (X651, X652, X654, and X656)
1
40X4425
1
1
MPF lift plate assembly with spring (X658)
2
40X4365
1
1
MPF 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 assembly with spring
11
40X4313
1
1
Pick arm sensor cable assembly
Parts catalog
7-11
Assembly 6: Drive motor assembly, redrive, and duplex
1
19
17
2
18
16
14
15
3
5
4
13
12
11
6
9
10
7
8
7-12 Service Manual
Assembly 6: Drive motor assembly, redrive, and duplex
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4467
1
1
Redrive assembly
2
40X5851
1
1
Duplex drive motor assembly
3
40X4346
1
5
Duplex assembly with 2 belts and 2 pulleys
4
40X4351
1
1
Duplex guide handle
5
40X4352
1
1
Duplex guide, rear
6
40X4353
1
1
Duplex guide spring, rear
7
40X4349
1
1
Duplex guide spring, right
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 and washer
• Bevel gear (1)
• Instruction sheet (1)
• Grease packet (1)
17
40X5749
1
1
Main drive motor assembly with option drive shaft
18
40X4386
1
1
Fuser drive release linkage
19
40X5850
1
1
Redrive motor assembly
Parts catalog
7-13
Assembly 7: Printhead, charge, and transfer assembly
1
11
12
2
10
9
8
7
6
5
7-14 Service Manual
4
3
Assembly 7: Printhead, charge, and transfer assembly
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4464
1
2
Printhead with cable assembly
2
40X1865
1
1
Printhead cable assembly
3
40X4317
1
1
Charge roll link 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 assembly
12
40X4369
1
1
Sensor (standard bin exit)
Parts catalog
7-15
Assembly 8: System card, HVPS and scanner controller card assemblies
X658
only
7-16 Service Manual
Assembly 8: System card, HVPS and scanner controller card assemblies
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4383
1
1
Cleaning blade contact
2
40X4381
1
1
Drum grounding contact
3
40X4382
3
1
Print cartridge HV contact
4
40X4370
1
1
Sensor (toner empty)
5
40X4362
1
1
HVPS card assembly
6
40X4361
1
1
HVPS / sensor cable assembly
7
40X4368
1
1
Sensor (input)
8
40X2019
1
1
Envelope / input option cable assembly (X658)
8
40X5848
1
1
Envelope / input option cable assembly (X651, X652, X654, and X656)
9
40X4501
1
1
System card assembly
10
40X7035
1
1
Hard drive cooling fan
11
40X4493
2
1
Scanner controller card interface cable assembly
12
40X4822
1
1
Hard drive assembly with board
12
40X5057
1
1
Hard drive assembly with board (TTA)
13
40X4821
1
1
Fax modem assembly with board
14
40X4496
1
1
Scanner controller card 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 replace one component at a time. replace the required component and perform a POR before replacing
a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Never replace two or more of the components listed above without a POR after installing each one or the
printer will be rendered inoperable.
These components 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.
Parts catalog
7-17
Assembly 9: Fuser and LVPS card assemblies
7-18 Service Manual
Assembly 9: Fuser and LVPS card assemblies
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X1870
1
1
Fuser assembly 100V, type 1
1
40X4418
1
1
Fuser assembly 110V, type 1
1
40X1871
1
1
Fuser assembly 220V, type 1
1
40X5853
1
1
Fuser assembly 100V, type 2
1
40X5854
1
1
Fuser 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
Sensor shield assembly
9
40X4379
1
1
Toner density sensor cable assembly
10
40X4378
1
1
Sensor (toner density)
Parts catalog
7-19
Assembly 10: Flatbed scanner
7-20 Service Manual
Assembly 10: Flatbed scanner
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X2165
1
1
Scanner unit assembly (X651, X652, X654, and X656)
1
40X2166
1
1
Scanner unit assembly (X658)
2
40X2642
1
1
Scanner platen glass cover assembly
3
40X4530
1
1
Scanner FB length sensor cable assembly
4
40X4527
1
1
Scanner exposure lamp
5
40X4526
1
1
Scanner CCD assembly
6
40X4534
1
1
Sensor (platen glass length) assembly
7
40X2641‘
1
1
Flatbed scanner interface card cable assembly
8
40X4523
1
1
Carriage belt
9
40X2171
1
1
Scanner interface card assembly
10
40X4521
1
1
Carriage drive motor assembly with cable
11
40X4528
1
1
Scanner reference LED cable assembly
12
40X4532
1
1
Scanner reference LED assembly
13
40X4524
1
1
Sensor (scanner HP) with bracket
14
40X4529
1
1
Scanner HP sensor cable assembly
15
40X4522
1
1
Carriage 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)
19
40X2172
1
1
Scanner CCD ribbon cable (X652, X654, and X656)
Warning: When replacing any of the following components:
• Scanner interface card assembly
• System card assembly
• Scanner unit assembly
Only replace one component at a time. replace the required component and perform a POR before replacing
a second component listed above. If this procedure is not followed, the printer will be rendered inoperable.
Never replace two or more of the components listed above without a POR after installing each one or the
printer will be rendered inoperable.
These components 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.
Parts catalog
7-21
Assembly 11: ADF unit assembly
1
7-22 Service Manual
Assembly 11: ADF unit assembly
Asmindex
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)
Parts catalog
7-23
Assembly 12: ADF covers
7-24 Service Manual
Assembly 12: ADF covers
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X4537
1
1
ADF top door assembly
2
40X3439
1
1
Left hinge assembly
3
40X2746
1
1
ADF cover cap, rear 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 assembly
Parts catalog
7-25
Assembly 13: ADF feed and drive
3
2
1
12
6
5
13
11
4
10
9
8
7
7-26 Service Manual
Assembly 13: ADF feed and drive
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X4540
1
1
ADF feed / pick roll assembly
2
40X4545
1
1
Spring
3
40X7213
1
3
Feed motor assembly with belt and cable
4
40X4544
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 limiter
13
40X2750
1
1
Bushing 6 mm
Parts catalog
7-27
Assembly 14: ADF electronics
7-28 Service Manual
Assembly 14: ADF electronics
Asmindex
Part
number
Units/
option
Units/
FRU
Description
1
40X6398
1
1
Spacer
2
40X4561
1
1
ADF document tray assembly
3
40X4559
1
1
ADF tray length cable assembly
4
40X4558
1
1
ADF sensor cable assembly 1
5
40X4606
1
1
Sensor (ADF media exit) bracket assembly (X651 and X652)
5
40X4607
1
1
Sensor (ADF media exit) bracket assembly with fan (X654, X656, and
X658)
6
40X4549
1
1
Sensor (ADF media exit)
7
40X4608
1
1
ADF filter and cover (X654, X656, and X658)
8
40X4556
1
1
ADF 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 assembly (X654, X656, and X658)
16
40X2762
1
1
Sensor (ADF 2nd scan)
17
40X4549
1
1
Sensor (ADF lower door interlock)
18
40X4560
1
1
ADF sensor cable assembly 2
19
40X4550
1
1
Sensor (ADF 1st scan)
20
40X4551
1
1
Sensor (ADF document set)
21
40X4550
1
1
Sensor (ADF sheet through)
22
40X4549
1
1
Sensor (ADF top door interlock)
Parts catalog
7-29
Assembly 15: 550 Sheet option tray assembly (X658)
7-30 Service Manual
Assembly 15: 550 Sheet option tray assembly (X658)
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X3967
1
1
Complete 550 sheet option tray assembly (X658)
2
40X3454
1
1
550 Sheet pick arm bracket assembly
3
40X4307
1
1
550 Sheet bellcrank recoil spring
4
40X4308
1
2
Pick roll assembly (2)
5
40X4369
1
1
Sensor (media low)
6
40X4369
1
1
Sensor (media empty)
7
40X4310
1
1
550 Sheet media out actuator
8
40X4570
2
2
Anti-tip latch assembly
9
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
40X4473
1
2
550 Option drive shaft with spring
18
40X4572
1
1
Lower interface cable assembly
19
40X3854
1
1
Media size actuator
20
40X4578
1
1
550 Sheet tray controller card assembly
21
40X4571
1
1
Upper interface cable assembly
Parts catalog
7-31
Assembly 16: 250 Sheet option tray assembly (X651, X652/5535dn,
X654, and X656)
1
7
3
6
5
2
4
18
8
17
16
15
14
9
10
13
11
12
7-32 Service Manual
Assembly 16: 250 Sheet option tray assembly (X651, X652/5535dn, X654,
and X656)
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4569
1
1
Complete 250 sheet option tray assembly
2
40X3447
1
1
250 Sheet pick arm bracket assembly
3
40X3448
1
1
250 Sheet bellcrank recoil spring
4
40X4308
2
1
Pick roll assembly (2)
5
40X4369
1
1
Sensor (media low)
6
40X4369
1
1
Sensor (media empty)
7
40X4309
1
1
250 Sheet media out actuator (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 actuator
17
40X4574
1
1
250 Sheet controller card assembly
18
40X4571
1
1
Upper interface cable assembly
Parts catalog
7-33
Assembly 17: 550 Sheet option tray assembly (X651, X652/5535dn,
X654, and X656)
7-34 Service Manual
Assembly 17: 550 Sheet option tray assembly (X651, X652/5535dn, X654,
and X656)
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4576
1
1
Complete 550 sheet option tray assembly
2
40X3454
1
1
550 Sheet pick arm bracket assembly
3
40X4307
1
1
550 Sheet bellcrank recoil spring
4
40X4308
1
2
Pick roll assembly (2)
5
40X4369
1
1
Sensor (media low)
6
40X4369
1
1
Sensor (media empty)
7
40X4310
1
1
550 Sheet media out actuator
8
40X4570
2
2
Anti-tip latch assembly
9
40X3957
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
17
40X4578
1
1
550 Sheet controller card assembly
18
40X4571
1
1
Upper interface cable assembly
Parts catalog
7-35
Assembly 18: HCIT Sheet option tray assembly (X651, X652/5535dn,
X654, and X656)
1
3
8
7
4
6
2
5
9
22
10
21
11
20
18
19
12
14
15
14
15
17
16
7-36 Service Manual
13
Assembly 18: HCIT Sheet option tray assembly (X651, X652/5535dn,
X654, and X656)
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4579
1
1
Complete HCIT option tray assembly
2
40X4590
1
2
HCIT pick arm bracket assembly
3
40X4595
1
1
Pick arm sensor cable assembly
4
40X4591
1
1
HCIT bellcrank recoil spring
5
40X4308
2
2
Pick roll assembly (2)
6
40X4369
2
1
Sensor (media low)
7
40X4310
1
1
550 Sheet media out actuator
8
40X4369
2
1
Sensor (media empty)
9
40X4581
1
1
HCIT cover, rear
10
40X4570
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
40X4594
1
1
HCIT interface cable assembly
20
40X4592
1
1
HCIT controller card assembly
21
40X4587
1
4
HCIT media size actuator assembly
22
40X4583
1
1
HCIT cover, left
Parts catalog
7-37
Assembly 19: MFP stapler assembly
1
7-38 Service Manual
Assembly 19: MFP stapler assembly #1
AsmIndex
1
Part
number
40X7026
Units/
mach
Units/ kit
or pkg
1
1
Description
MFP stapler assembly (comes completely assembled)
Parts catalog
7-39
Assembly 20: MFP stapler assembly #2
1
19
18
17
2
3
16
14
4
5
15
7
13
6
8
12
11
9
10
7-40 Service Manual
Assembly 20: MFP stapler assembly #2
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4612
1
1
Handle cover
2
40X4613
1
1
Rear door assembly
3
40X4730
1
1
Stapler cover
4
40X4764
1
1
Hollow cover
5
40X4610
1
1
Right cover
6
40X5544
1
1
Sensor (bin full 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
Left cover
18
40X4611
1
1
Top cover
19
40X5906
1
1
Sensor (stapler/stacker pass through)
Parts catalog
7-41
Assembly 21: MFP stapler assembly #3
1
11
2
3
10
6
4
5
8
6
7
9
7-42 Service Manual
Assembly 21: MFP stapler assembly #3
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4645
1
1
Media stack flap actuator
2
40X4646
1
1
Media stack flap
3
40X4369
1
1
Sensor (media stack)
4
40X4621
1
1
Left tamper motor assembly
5
40X4622
1
1
Right tamper motor assembly
6
40X4624
1
2
Tamper recoil spring
7
40X4369
1
1
Sensor (tamper HP right)
8
40X4369
1
1
Sensor (tamper HP left)
9
40X4623
1
1
Tamper drive belt
10
40X4369
1
1
Sensor (paddle HP)
11
40X4615
1
1
Paddle drive motor
Parts catalog
7-43
Assembly 22: MFP stapler assembly #4
1
2
7-44 Service Manual
Assembly 22: MFP stapler assembly #4
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4641
1
1
Stapler assembly
2
40X5909
1
1
Sensor (media in stapler)
Parts catalog
7-45
Assembly 23: MFP offset stacker assembly #1
1
7-46 Service Manual
Assembly 23: MFP offset stacker assembly #1
AsmIndex
1
Part
number
40X7025
Units/
mach
Units/ kit
or pkg
1
1
Description
MFP offset stacker assembly (comes completely assembled)
Parts catalog
7-47
Assembly 24: MFP Offset stacker #2
1
18
17
16
2
15
3
13
4
14
6
12
5
7
10
11
8
9
7-48 Service Manual
Assembly 24: MFP Offset stacker #2
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4612
1
1
Handle cover
2
40X4613
1
1
Rear door assembly
3
40X4730
1
1
Stapler cover
4
40X4610
1
1
Right cover
5
40X5544
1
1
Sensor (bin full receive)
6
40X4617
1
2
Finisher bin spring
7
40X5545
1
1
Standard output bin LED
8
40X5727
1
1
LED clear lens
LED sensor cover
9
40X5720
1
1
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
40X4611
1
1
Top cover
18
40X5906
1
1
Sensor (stapler/stacker pass through)
Parts catalog
7-49
Assembly 25: MFP Offset stacker #3
1
11
2
3
10
6
4
5
8
6
7
9
7-50 Service Manual
Assembly 25: MFP Offset stacker #3
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4645
1
1
Media stack flap actuator
2
40X4646
1
1
Media stack flap
3
40X4369
1
1
Sensor (media stack)
4
40X4621
1
1
Left tamper motor assembly
5
40X4622
1
1
Right tamper motor assembly
6
40X4624
1
2
Tamper recoil spring
7
40X4369
1
1
Sensor (tamper HP right)
8
40X4369
1
1
Sensor (tamper HP left)
9
40X4623
1
1
Tamper drive belt
10
40X4369
1
1
Sensor (paddle HP)
11
40X4615
1
1
Paddle drive motor
Parts catalog
7-51
Assembly 26: MFP 4-bin mailbox assembly #1
1
7-52 Service Manual
Assembly 26: MFP 4-bin mailbox assembly #1
AsmIndex
1
Part
number
40X7024
Units/
mach
Units/ kit
or pkg
1
1
Description
MFP 4 bin mailbox assembly (comes completely assembled)
Parts catalog
7-53
Assembly 27: MFP 4-bin mailbox assembly #2
1
3
2
11
9
10
4
8
6
7
7-54 Service Manual
5
Assembly 27: MFP 4-bin mailbox assembly #2
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X4644
1
1
Top media 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
Parts catalog
7-55
Assembly 28: MFP 4-bin mailbox assembly #3
12
1
11
2
3
4
10
4
8
9
8
9
8
9
8
9
5
6
7
7-56 Service Manual
Assembly 28: MFP 4-bin mailbox assembly #3
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
1
40X5750
4
1
Spring
2
40X5728
2
1
Sensor (pass through)
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
Parts catalog
7-57
Assembly 29: Envelope feeder
1
7-58 Service Manual
Assembly 29: Envelope feeder
AsmIndex
1
Part
number
40X5739
Units/
mach
Units/ kit
or pkg
1
1
Description
Envelope feeder (X658 only)
Parts catalog
7-59
Assembly 30: Miscellaneous
AsmIndex
NS
Part
number
7372935
Units/
mach
Units/ kit
or pkg
1
1
Description
Relocation kit (X651, X652, and X654)
NS
7377730
1
1
Relocation kit (X658)
NS
40X4723
1
1
Printer maintenance kit (100 V type 1 fuser)
NS
40X4724
1
1
Printer maintenance kit (110 V type 1 fuser)
NS
40X4765
1
1
Printer maintenance kit (220 V type 1 fuser)
NS
40X4766
1
1
Printer maintenance kit (100 V type 2 fuser)
NS
40X4767
1
1
Printer maintenance kit (110 V type 2 fuser)
NS
40X4768
1
1
Printer maintenance kit (220 V type 2 fuser)
NS
40X4769
1
1
ADF maintenance kit
NS
40X5301
1
1
256 MB SO-DIMM
NS
40X5302
1
1
512MB SO-DIMM
NS
40X5303
1
1
1GB (1024MB) SO-DIMM
NS
40X5704
1
1
256MB user flash memory card
NS
40X5057
1
1
TAA hard drive assembly with connector
NS
40X5952
1
1
LXK PrintCryption card
NS
40X5969
1
1
Korean font card
NS
40X5970
1
1
Simplified Chinese font card
NS
40X5971
1
1
Traditional Chines font card
NS
40X5972
1
1
Japanese font card
NS
40X5953
1
1
Bar code/forms card
NS
40X5958
1
1
IPDS card (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 wireless print server (WW, except US/Americas)
NS
56P2129
1
1
LXK N4000e print server
NS
56P2744
1
1
LXK N4050e (1 port USB) wireless 802.11g (US/Americas)
NS
40X1593
1
1
LXK MarkNet N7002e (1 port parallel) ethernet 10baseT/100BaseTX
NS
40X1594
1
1
LXK MarkNet N7002e (1 port parallel) ethernet 10base T/100Base TX
NS
40X1592
1
1
LXK MarkNet N7020e (4 port USB) ethernet 10base T/100Base TX/
1000BaseT
NS
40X4819
1
1
RS-232C serial interface card
NS
40X4823
1
1
Parallel 1284-B interface card
NS
40X1367
1
1
10-Foot parallel printer cable
NS
40X1368
1
1
2-Meter USB printer cable
NS
40X4821
1
1
MarkNet N8110-v.34 fax card
NS
40X5606
1
1
Fax interface card assembly
NS
40X2665
1
1
Fuser oil wiper (black housing)
NS
40X2666
1
1
Fuser wax wiper (gray housing)
7-60 Service Manual
Assembly 30 (continued): Miscellaneous
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
1
Description
NS
40X1462
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)
Parts catalog
7-61
Assembly 31: Power cords
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
NS
40X0269
1
1
Power cord LV, USA & Canada, Latin America
NS
40X0288
1
1
Power cord HV, Argentina
NS
40X0273
1
1
Power cord HV, Chile, Uruguay
NS
40X3141
1
1
Power cord HV, Paraguay, Austria, Belgium, France, Germany, Italy,
Netherlands, Bluemark, Czech & Solvic countries, Greece, Hungary,
Medmark 1, Medmark 2, Arabic, Poland, Russia, CIS, Spain, Portugal, &
Ireland
NS
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
NS
40X1791
1
1
Power cord LV, Taiwan
NS
40X1774
1
1
Power cord HV, Denmark, Finland, Norway, Sweden
NS
40X0275
1
1
Power cord, HV, Israel
NS
40X1773
1
1
Power cord HV, South Africa, Namibia, Lesotho, Botswana & Pakistan
NS
40X1772
1
1
Power cord HV, Switzerland
7-62 Service Manual
Assembly 32: Universal trays and accessories
AsmIndex
Part
number
Units/
mach
Units/ kit
or pkg
Description
NS
40X5857
1
1
Universal media drawer with tray, 200 sheet (X651, X652, X654, and X656)
NS
40X5858
1
1
Universal media tray, 200 sheet (X651, X652, X654, and X656)
NS
40X5859
1
1
Universal media drawer with tray, 400 sheet (X651, X652, X654, and X656)
NS
40X5860
1
1
Universal media tray, 400 sheet (X651, X652, X654, and X656)
Wear strips, smooth 250 sheet
NS
40X7001
1
1
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
Wear strips, 4 row dimpled 550 sheet
NS
40X7009
1
1
250 sheet tray replacement wear strip kit
NS
40X7010
1
1
550 sheet tray replacement wear strip kit
NS
40X0392
1
1
Klear screen wipe
Parts catalog
7-63
7-64 Service Manual
Index
A
acronyms 1-9
ADF & scanner image quality
dark image quality 2-173
adjustments
fuser solenoid 4-4
gap adjustment 4-4
ASIC Test 3-27
B
Button Test 3-14
buttons
accessing service menus 3-7
Button Test 3-14
C
CACHE Test 3-15
Configuration ID 3-23
configuration menu
accessing 3-7, 3-28
ADF Edge Erase 3-34
available menus 3-28
Disk Encryption 3-38
Energy Conserve 3-33
Envelope Prompts 3-36
Factory Defaults 3-33
FB Edge Erase 3-35
Font Sharpening 3-39
Format Fax Storage 3-34
Jobs On Disk 3-38
Key Repeat Initial Delay 3-40
Key Repeat Rate 3-40
LES Applications 3-40
Maintenance Page Count 3-29
Min Copy Memory 3-34
Panel Menus 3-32
Paper Prompts 3-36
PPDS Emulation 3-32
Print Quality Pages 3-30
Require Standby 3-39
Reset Maintenance Counter 3-29
SIZE SENSING 3-31
Wipe Disk 3-39
Wiper Message 3-40
copy skew correction 3-101
D
defaults
EP defaults 3-24
factory 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 3-17
EP SETUP
Charge Roll 3-25
EP Defaults 3-24
Fuser Page Count 3-24
Fuser Temp 3-24
Gap Adjust 3-25
Print Contrast 3-25
Transfer 3-25
Warm Up Time 3-24
EVENT LOG
Clear Log 3-26
Display Log 3-25
Print Log 3-26
exiting 3-10
HARDWARE TESTS
Button Test 3-14
CACHE Test 3-15
DRAM Test 3-15
Panel Test 3-14
INPUT TRAY TESTS
Feed Test 3-19
Sensor Test 3-19
OUTPUT BIN TESTS
Feed Test 3-20
Sensor Tests 3-20
PRINT TESTS
input source 3-12
Prt Quality Pgs 3-13
PRINTER SETUP
Configuration ID 3-23
Defaults 3-22
Edge to Edge 3-23
engine settings 3-22
Model Name 3-22
Page Count 3-22
Perm Page Count 3-22
Serial Number 3-22
REGISTRATION 3-11
Quick Test 3-12
Index
I-1
SCANNER TESTS
ASIC Test 3-27
Feed Test 3-27
Sensor Tests 3-27
Disk Encryption 3-38
DRAM Test 3-15
Duplex 3-82
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 3-17
E
Edge to Edge 3-23
Energy Conserve 3-33
Engine Setting 3-22
Envelope Prompts 3-36
error codes
200.00 sensor (registration) late jam 2-127, 2-137,
2-139
200.01 sensor (registration) lag jam 2-129
290.01 sensor (sheet through) late jam 2-113
290.02 sensor (ADF pre-registration) late jam (side 1)
2-114
290.03 sensor (ADF pre-registration) lag jam 2-115
291.01 sensor (ADF inverter) lag jam (inverting) 2-119,
2-121, 2-125
ESD-sensitive parts 4-1
event log
clear log (diagnostics menu) 3-26
display log (diagnostics mode) 3-25
print log (diagnostics menu) 3-26
F
Feed Test (scanner) 3-27
Font Sharpening 3-39
Format Fax Storage 3-34
fuser solenoid
adjustment 4-4
G
gap adjustment 3-25, 4-4
I
image quality trouble 2-152
blank print (no print) 2-155
faint print (low contrast) 2-153
image quality 2-153, 2-173
solid 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
I-2 Service Manual
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 tests 3-12
input tray feed test 3-19
J
Jobs On Disk 3-38
K
Key Repeat Initial Delay 3-40
Key Repeat Rate 3-40
L
LES Applications 3-40
LXK Embedded Solution 3-40
lithium battery ii-xxiii, 4-50
lubrication specifications 6-1
M
maintenance
maintenance kit 6-2
maintenance approach 1-1
Media 3-98
media squareness check 3-98
menus
accessing service menus 3-7
configuration menu 3-28
diagnostics menu 3-8
Min Copy Memory 3-34
Model Name 3-22
models 1-1
O
operator panel
Button Test 3-14
Panel Test 3-14
options
descriptions 1-3
options and features
description 1-2
output bin sensor tests 3-20
P
page count
Fuser Page Count 3-24
Page Count 3-22
permanent page count 3-22
Panel Menus 3-32
Panel Test 3-14
Paper Prompts 3-36
parts catalog
covers 7-24
PPDS Emulation 3-32
Print 3-99
print quality pages 3-13, 3-30
print registration 3-11
print skew correction 3-99
printer overview 1-2
printer theory 3-43
control 3-61
fuser control 3-61
printhead control 3-61
document scanning 3-68
document scanning at platen 3-68
drive 3-58
electrical components and controller 3-59
exit 3-58
functions of main components 3-44
media tray assembly 3-44, 3-79
rear media guide 3-45, 3-79
media tray assembly 3-46, 3-80
detection of media size 3-47, 3-80
sensor (feed-out) 3-48
sensor (media level) 3-48, 3-81
sensor (media out) 3-47, 3-81
switch (media size) 3-47, 3-81
multi-purpose feeder (MPF) 3-48
MPF feed roll 3-48
MPF pick solenoid 3-48
sensor (MPF media out) 3-49
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 during a print cycle 3-62
T
tools 3-77
Top Margin
duplex 3-17
simplex (front side) 3-11
U
unique tools 3-77
W
warm up time 3-24
Wipe Disk 3-39
Wiper Message 3-40
Q
quality pages 3-13, 3-30
Quick Disk Test 3-21
Quick Test 3-12, 3-16
R
REGISTRATION 3-11
registration 3-11
Require Standby 3-39
S
safety information ii-xxiii
safety inspection guide 6-1
scheduled maintenance 6-2
serial number 3-22
Service checks 2-107
Index
I-3
I-4 Service Manual
Part number index
P/N
40X0269
40X0271
40X0273
40X0275
40X0288
40X0301
40X0303
40X0392
40X1367
40X1368
40X1462
40X1463
40X1464
40X1556
40X1592
40X1593
40X1594
40X1772
40X1773
40X1774
40X1791
40X1792
40X1863
40X1864
40X1865
40X1866
40X1868
40X1869
40X1870
40X1871
40X1876
40X1883
40X1886
40X1887
40X1888
40X1900
40X1915
40X1916
40X1917
40X1918
40X1919
40X1970
40X1971
40X1972
40X1973
40X1974
40X1975
40X1975
40X1976
40X1976
40X1977
40X2016
Description
Page
Power cord LV, USA & Canada, Latin America - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord HV, Chile, Uruguay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord, HV, Israel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord HV, Argentina - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord HV, Australia & New Zealand - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord, HV PRC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Klear screen wipe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
10-Foot parallel printer cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
2-Meter USB printer cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Locking universal media drawer with tray, 200 sheet (excluding X658) - - - - - - - - - - - - - - - - - - - - - - - - 7-61
Locking media drawer with tray, 550 sheet (excluding X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-61
Locking universal media drawer with tray, 400 sheet (excluding X658) - - - - - - - - - - - - - - - - - - - - - - - - 7-61
Parts pack, ISP thumbscrew and standoff - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
LXK MarkNet N7020e (4 port USB) ethernet 10base T/100Base TX/1000Base T - - - - - - - - - - - - - - - - 7-60
LXK MarkNet N7002e (1 port parallel) ethernet 10base T/100Base TX - - - - - - - - - - - - - - - - - - - - - - - 7-60
LXK MarkNet N7002e (1 port parallel) ethernet 10base T/100Base TX - - - - - - - - - - - - - - - - - - - - - - - 7-60
Power cord HV, Switzerland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord HV, South Africa, Namibia, Lesotho, Botswana & Pakista - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord HV, Denmark, Finland, Norway, Sweden - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord LV, Taiwan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Power cord, HV, Korea - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
250 Option drive shaft with spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
Print cartridge ID connector assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Printhead cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Sensor shield assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Print cartridge clamp assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Transfer deflector with static brush - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Fuser assembly 100V, type 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Fuser assembly 220V, type 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
MPF gear shield - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
MPF pick roll assembly with flange and clip - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Transfer roll assembly with tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Transfer roll bracket with cable assembly, left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Transfer roll bracket assembly, right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Media turn guide with actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Model door bezel (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Side cover, left (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Side cover, right (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Laser cover assembly, 550 sheet(X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - 7-3
Output cover assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Laser cover assembly, 550 sheet (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Inner cover, left (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Inner cover, right (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Media support (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Stapler access cover (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
550 Sheet tray left cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
Tray cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
550 Sheet tray right cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
Tray cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Print cartridge cover assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
MPF tray cover assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Part number index
I-5
40X2017
40X2018
40X2019
40X2045
40X2062
40X2072
40X2074
40X2075
40X2077
40X2078
40X2089
40X2149
40X2164
40X2164
40X2165
40X2166
40X2169
40X2171
40X2172
40X2638
40X2641
40X2642
40X2643
40X2665
40X2666
40X2738
40X2745
40X2746
40X2749
40X2750
40X2759
40X2760
40X2761
40X2762
40X2786
40X2787
40X2788
40X3141
40X3142
40X3272
40X3392
40X3438
40X3439
40X3444
40X3445
40X3447
40X3448
40X3453
40X3454
40X3609
40X3822
40X3854
40X3957
40X3967
40X4000
40X4121
40X4123
Media support (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Operator panel front cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Envelope / input option cable assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Operator panel cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - 7-3
LVPS card assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
LVPS card assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Scanner controller card assembly (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Scanner controller card assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Counter balance spring (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Spring connector (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
MPF tray door assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Operator panel door assembly with hinges (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Media tray assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Media tray assembly, 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
Scanner unit assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner unit assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner cover plug, rear (X651) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner interface card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner CCD ribbon cable (X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Standard output bin LED assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - 7-3
Flatbed scanner interface card cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner platen glass cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Standard output bin LED cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Fuser oil wiper (black housing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Fuser wax wiper (gray housing) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
ADF unit assembly (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
ADF unit assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-23
ADF cover cap, rear left (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Feed one-way bearing and gear kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Bushing 6 mm - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Transport drive gear and pulley kit, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Transport drive gear, pulley, and belt kit, front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Pick roll position cam assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Sensor (ADF 2nd scan) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Wear strips, 4 row dimpled 250 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
Wear strips, 3 row dimpled 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
Wear strips, 4 row dimpled 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
Power cord HV, Paraguay, Austria, Belgium, France, Germany, Italy, Netherlands, Bluemark, Czech &
Solvic countries, Greece, Hungary, Medmark 1, Medmark 2, Arabic, Poland, Russia, CIS, Spain,
Portugal, & Ireland - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
ADF controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF duplex deletion insert (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF lower door assembly (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF lower door assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Left hinge assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF platen cushion - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Media pinch pad assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
250 Sheet pick arm bracket assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
250 Sheet bellcrank recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
250 Sheet option drawer assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
550 Sheet pick arm bracket assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-35
Power cord 100 V, Japan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Media tray catch spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
Media size actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
550 Sheet option drawer assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
Complete 550 sheet option tray assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
X654de touch screen bezel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
X656de touch screen bezel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
X651de touch screen bezel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
I-6 Service Manual
40X4130
40X4135
40X4136
40X4138
40X4139
40X4303
40X4305
40X4307
40X4307
40X4308
40X4309
40X4310
40X4310
40X4313
40X4316
40X4317
40X4318
40X4331
40X4335
40X4345
40X4346
40X4348
40X4349
40X4350
40X4351
40X4352
40X4353
40X4354
40X4356
40X4357
40X4359
40X4360
40X4361
40X4362
40X4364
40X4365
40X4368
40X4369
40X4369
40X4369
40X4369
40X4369
40X4369
40X4369
40X4369
40X4369
40X4370
40X4372
40X4376
40X4377
40X4378
40X4379
40X4381
40X4382
40X4383
40X4384
40X4385
40X4386
40X4388
Cover, 550 sheet tray front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
1st - 3rd media bail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Media bin full actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Media bin deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Media output bin light pipe - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Alignment assembly with ground strap and adj. screw - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
550 Sheet pick arm assembly with spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
550 Sheet bellcrank recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-35
Pick arm spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Pick roll assembly (2) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11, 7-31, 7-33, 7-35, 7-37
250 Sheet media out actuator (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
550 Sheet media out actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11, 7-31, 7-37
550 Sheet media out actuator (T652 and T654) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
Pick arm sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Charge roll link spring, left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Charge roll link spring, right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Fuser access door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Door assembly, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-5
Cover assembly, rear lower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-5
Duplex input sensor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex assembly with 2 belts and 2 pulleys - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex guide assembly, front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex guide spring, right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex drive belt, lower - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex guide handle - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex guide, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex guide spring, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex drive belt, upper - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex cooling fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Duplex cooling fan cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Print cartridge cooling fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Print cartridge cooling fan cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
HVPS / sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
HVPS card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Main cooling fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
MPF pick solenoid assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Sensor (input) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Sensor (deflector gate HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Sensor (duplex input) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Sensor (media empty) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35, 7-37
Sensor (media low) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35, 7-37
Sensor (media stack) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Sensor (paddle HP) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Sensor (standard bin exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Sensor (tamper HP left) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Sensor (tamper HP right) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Sensor (toner empty) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Sensor (standard bin exit) actuator assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Output option interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
USB cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Sensor (toner density) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Toner density sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Drum grounding contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Print cartridge HV contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Cleaning blade contact - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
EP cooling fan duct - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Envelope feeder interface cover (X658 only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Fuser drive release linkage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Inner deflector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Part number index
I-7
40X4389
40X4390
40X4392
40X4394
40X4395
40X4395
40X4406
40X4417
40X4418
40X4419
40X4425
40X4457
40X4459
40X4464
40X4467
40X4469
40X4469
40X4470
40X4472
40X4473
40X4473
40X4475
40X4476
40X4477
40X4478
40X4479
40X4480
40X4481
40X4483
40X4484
40X4485
40X4486
40X4489
40X4491
40X4492
40X4493
40X4496
40X4498
40X4499
40X4500
40X4501
40X4503
40X4504
40X4505
40X4506
40X4507
40X4508
40X4509
40X4510
40X4511
40X4512
40X4513
40X4514
40X4515
40X4516
40X4517
40X4518
40X4519
40X4520
LVPS cooling duct - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Machine pad - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Main cooling duct (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Tray catch spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Media tray roller catch assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
Tray roller catch assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Print cartridge support roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Fuser wiper cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Fuser assembly 110V, type 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Fuser interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
MPF lift plate assembly with spring (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
MPF cam gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
MPF lift plate assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
Printhead with cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Redrive assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Media tray assembly, 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
Media tray assembly, 550 sheet (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - 7-11
Output bail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-5
Switch (media size assembly) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-11
550 Option drive shaft with spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-35
Option drive shaft with spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Access door (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Side cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Corner cover, left rear (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Side cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Corner cover, right rear (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Output cover assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Access door (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
MPF tray cover support strap (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Inner cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Inner cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Main cooling fan duct (X658DE) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-9
Print cartridge recoil spring (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-5
Operator panel bezel (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Operator panel cable assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner controller card interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Scanner controller card power cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
LVPS cooling fan cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Standard output bin LED cable assembly (X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
USB cable assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
System card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Operator panel door assembly with hinges (X654 and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Operator panel assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner cover, front (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner cover, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner cover, left (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner cover, right (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner support platform (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Scanner cover, rear (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner cover, front (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support cover, left front (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support cover, left rear (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support cover, right rear (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support inner cover, left (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner support inner cover, right (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
I-8 Service Manual
40X4521
40X4522
40X4523
40X4524
40X4525
40X4526
40X4527
40X4528
40X4529
40X4530
40X4531
40X4532
40X4534
40X4535
40X4536
40X4537
40X4538
40X4539
40X4540
40X4542
40X4544
40X4545
40X4547
40X4548
40X4549
40X4549
40X4549
40X4550
40X4550
40X4551
40X4554
40X4555
40X4556
40X4557
40X4558
40X4559
40X4560
40X4561
40X4562
40X4563
40X4564
40X4565
40X4566
40X4569
40X4570
40X4571
40X4572
40X4574
40X4575
40X4576
40X4578
40X4578
40X4579
40X4580
40X4581
40X4582
40X4583
40X4584
40X4585
Carriage drive motor assembly with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Carriage belt tensioner assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Carriage belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Sensor (scanner HP) with bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Standard output bin LED assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Scanner CCD assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner exposure lamp - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner reference LED cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner HP sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner FB length sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner CCD ribbon cable (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner reference LED assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Sensor (platen glass length) assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner cooling fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
Scanner cooling fan filter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-21
ADF top door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF cover, front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF cover, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF feed / pick roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Pinch roll assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Transport motor bracket assembly with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
ADF duplex CCD assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF solenoid assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Sensor (ADF lower door interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF media exit) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF top door interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF 1st scan) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF sheet through) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF document set) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Switch (ADF closed interlock) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Duplex CCD interface cable assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF closed interlock switch cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF sensor cable assembly 1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF tray length cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF sensor cable assembly 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF document tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Pick pad cover assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Right hinge assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Document tray extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
ADF duplex CCD scan glass assembly (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
ADF turn guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-25
Complete 250 sheet option tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
Anti-tip latch assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35, 7-37
Upper interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
Lower interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
250 Sheet controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
Sensor (pass through) with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31, 7-33, 7-35
Complete 550 sheet option tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
550 Sheet controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-35
550 Sheet tray controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
Complete HCIT option tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT media tray assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT cover, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT cover, right - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT cover, left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT tray cover, front - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT tray closed latch with spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Part number index
I-9
40X4586
40X4587
40X4588
40X4589
40X4590
40X4591
40X4592
40X4593
40X4594
40X4595
40X4596
40X4598
40X4599
40X4600
40X4601
40X4602
40X4603
40X4604
40X4605
40X4606
40X4607
40X4608
40X4609
40X4610
40X4611
40X4612
40X4613
40X4615
40X4617
40X4618
40X4619
40X4621
40X4622
40X4623
40X4624
40X4625
40X4626
40X4629
40X4631
40X4632
40X4633
40X4634
40X4635
40X4636
40X4637
40X4638
40X4639
40X4640
40X4641
40X4642
40X4643
40X4644
40X4645
40X4646
40X4647
40X4723
40X4724
40X4730
40X4764
HCIT tray lift drive motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT media size actuator assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Sensor (HCIT tray raised HP) with cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Sensor (HCIT pass through) with cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT pick arm bracket assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT bellcrank recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT drawer slide assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
HCIT interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Pick arm sensor cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-37
Power cord LV, Brazil PPB kits - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-62
Card reader cover assembly (X651, X652/5535dn, X654, and-X656)
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Operator panel cover with card reader slot (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Card reader cable assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-7
Card reader cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Card reader assembly (3121 contact) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7
Card reader assembly (5121 contact/RFID) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7
Card reader assembly (5125 contact/HID) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3, 7-7
ADF separator roll and guide - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-27
Sensor (ADF media exit) bracket assembly (X651 and X652/5535dn) - - - - - - - - - - - - - - - - - - - - - - - 7-29
Sensor (ADF media exit) bracket assembly with fan (X654, X656, and X658) - - - - - - - - - - - - - - - - - - 7-29
ADF filter and cover (X654, X656, and X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Left cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Right cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Top cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Handle cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Rear door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Paddle drive motor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Finisher bin spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Sensor (finisher bin media present) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Media output bin extension - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Left tamper motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Right tamper motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Tamper drive belt - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Tamper recoil spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Stapler/stacker controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Sensor (bin full send) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Connection bezel assembly, rear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
Operator panel door latch assembly (MFP X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - 7-3
Rear door assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Sensor (media bin full) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
4 bin mailbox controller card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Deflector gate solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
LED card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Right rear inner cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Left rear inner cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Right cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Left cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Stapler assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
Top cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Transport solenoid - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Top media bin bail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-55
Media stack flap actuator - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Media stack flap - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-43, 7-51
Output bin LED bracket - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Printer maintenance kit (100 V type 1 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Printer maintenance kit (110 V type 1 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Stapler cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Hollow cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41
I-10 Service Manual
40X4765
40X4766
40X4767
40X4768
40X4769
40X4819
40X4821
40X4821
40X4822
40X4823
40X4826
40X4827
40X5038
40X5039
40X5057
40X5057
40X5301
40X5302
40X5303
40X5316
40X5541
40X5544
40X5545
40X5551
40X5606
40X5704
40X5720
40X5727
40X5728
40X5739
40X5749
40X5750
40X5751
40X5757
40X5843
40X5848
40X5850
40X5851
40X5852
40X5853
40X5854
40X5855
40X5857
40X5858
40X5859
40X5860
40X5906
40X5909
40X5952
40X5953
40X5958
40X5969
40X5970
40X5971
40X5972
40X6200
40X6391
40X6398
40X7001
Printer maintenance kit (220 V type 1 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Printer maintenance kit (100 V type 2 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Printer maintenance kit (110 V type 2 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Printer maintenance kit (220 V type 2 fuser) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
ADF maintenance kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
RS-232C serial interface card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Fax modem assembly with board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
MarkNet N8110-v.34 fax card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Hard drive assembly with board - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
Parallel 1284-B interface card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
MarkNet N8120 gigabit ethernet print server - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
MarkNet N8130 fiber ethernet print server - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
MarkNet N8150 802.11n wireless print server (US/Americas) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
MarkNet N8150 802.11n wireless print server (WW, except US/Americas) - - - - - - - - - - - - - - - - - - - - - 7-60
Hard drive assembly with board (TTA) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-17
TAA hard drive assembly with connector - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
256 MB SO-DIMM, DDR2 for T654 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
12MB SO-DIMM, DDR2 for T654 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
1GB (1024MB) SO-DIMM, DDR2 for T654 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
ISP interface cable assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Media output bin - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Sensor (bin full receive) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Standard output bin LED - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49, 7-57
Duplex guide spring, left - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Fax interface card assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
256MB user flash memory card for T65X - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
LED sensor cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
LED clear lens - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49, 7-57
Sensor (pass through) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Envelope feeder (X658 only) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-59
Main drive motor assembly with option drive shaft - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Spring - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-57
Attach roller - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49, 7-57
X652de touch screen bezel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-3
550 Sheet option drawer assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-31
Envelope / input option cable assembly (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - 7-17
Redrive motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Duplex drive motor assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-13
Charge roll assembly with tool - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-15
Fuser assembly 100V, type 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Fuser assembly 110V, type 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Fuser assembly 220V, type 2 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-19
Universal media drawer with tray, 200 sheet (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - 7-63
Universal media tray, 200 sheet (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - 7-63
Universal media drawer with tray, 400 sheet (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - 7-63
Universal media tray, 400 sheet (X651, X652/5535dn, X654, and X656) - - - - - - - - - - - - - - - - - - - - - - - 7-63
Sensor (stapler pass through) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-41, 7-49
Sensor (media in stapler) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-45
LXK PrintCryption card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Bar code/forms card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
IPDS card (available w/EMEA, AP, LAD - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Korean font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Simplified Chinese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Traditional Chines font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Japanese font card - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Forms card with P269UBC code for UBOC - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-60
Media tray assembly, 250 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-33
Spacer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-29
Wear strips, smooth 250 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-63
Part number index
I-11
40X7002
40X7003
40X7004
40X7009
40X7010
40X7024
40X7025
40X7026
40X7035
40X7047
40X7204
40X7213
40X7214
56P2129
56P2744
7372935
7377730
99A0954
99A1206
Wear strips, dimpled 250 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Wear strips, 3 row dimpled 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Wear strips, dinky 550 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 250 sheet tray replacement wear strip kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 550 sheet tray replacement wear strip kit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MFP 4 bin mailbox assembly (comes completely assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - MFP offset stacker assembly (comes completely assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - MFP stapler assembly (comes completely assembled) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Hard drive cooling fan - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MPF media guide assembly (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Scanner filer cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Feed motor assembly with belt and cable - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Torque limiter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LXK N4000e print server - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - LXK N4050e (1 port USB) wireless 802.11g (US/Americas) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Relocation kit (X651, X652/5535dn, and X654) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Relocation kit (X658) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Bevel gear with grease packet and washer - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Wear strips, 3 row dimpled 250 sheet - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
I-12 Service Manual
7-63
7-63
7-63
7-63
7-63
7-53
7-47
7-39
7-17
7-5
7-21
7-27
7-27
7-60
7-60
7-60
7-60
7-13
7-63
Print defects guide
Page 1 of 1
Print defects guide
Match a set of repeating defects on a print job to the marks on one of the vertical lines. The line that best
matches the defects on the print job indicates which particular part may be causing the defect.
For example, the distance between these two marks represents
a repeating defect that occurs every 28.3 mm (1.11 in.), which
means the charge rollers may need to be replaced.
Note: If the defect appears on the printed side of a single-sided print
job, replace the toner cartridge before replacing the fuser.
Replace the toner cartridge
47.8 mm
(1.88 in.)
Replace the
transfer roller
51.7 mm
(2.04 in.)
Replace the
charge rollers
28.3 mm
(1.11 in.)
96.8 mm
(3.81 in.)
Replace the fuser
88.0 mm
(3.46 in.)
95.2 mm
(3.75 in.)
1
250V
CR08
Fuser
Power
TBD
2
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
CN3
Card Assembly
LVPS
CN3
3 2 1
250V
F2
Power
Switch
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Fax Card Assembly
3 2 1
Sensor
(STD Bin Full)
3 2 1
3 2 1
S HOP LED
GND
S HOP FULL*
13 12 11 10 9 8 7 6 5 4 3 2 1
J23
Duplex Drive
Motor Assembly
Sensor
(Duplex Input)
Duplex
Cooling Fan
5 4 3 2 1
1 2 3
1 2
1 2
1 2
1 2
1 2 3
5 4 3
INA PORT
1
3
To J22 [2]
5
4
To J22 [1]
6
To J32 [3]
7
2
Output Option
Interface
To J32 [4]
8
1 2 3 4
1 2 3 4
JDC2
JDC1
JFX2
(To Scanner Controller Card J42)
J14
JDIMM1
1 2 3
2 1
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
ISP
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1 2 3 4 5
J25 USB Device Port
J21
Ethernet
J18
1 2 3 4 5 6 7 8 9 10 11 12 13 14
1
2
3
4
5
6
7
8
9
10
11
12
13
14
JFX1
System Card Assembly
AIO POWER J10
10 9 8 7 6
5 4 3 2 1
4
3
2
1
4
3
2
1
4
3
2
1
CN1
1 2 3 4
Pick Arm Assembly
14 15
11 12 13
8 9 10
1 2 3
5 6 7
MPF Pick
Solenoid
1 2
1 2 3
1 2 3
1 2
1 2
GND
S TX OPT
GND
S RX OPT
1 2 3
7
6
5
4
3
2
1
5
4
3
2
1
13
12
11
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
7
6
5
4
3
2
1
5
4
3
2
1
13
12
11
10
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
12
11
10
9
8
7
6
5
4
3
2
1
GND
DATA FUSER
CLK FUSER
FUSER 3V
EXIT SNS*
GND
+5V SW
THUMP SOL DRV
FLIPPER DRV*
F THERM
GND
NAR MEDIA*
BLDC WIND 2
BLDC WIND 1
BLDC WIND 0
+5V SW
GND
BLDC FG R
BLDC HALL 2 R
BLDC HALL 1 R
BLDC HALL 0 R
GND
S TONER WHEEL*
S TWHEEL LED
S IN SENSE LED
S IN SENSE*
GND
S DEV
GND
S CHARGE
S +24V SW
S XFR
S TX ENB
S AT SERVO
S TDS +5V
GND
S TDS SIG
NC TDS -4
GND
1
2
3
12
11
10
9
8
7
6
5
4
3
2
1
6
To J26 [2]
2
5
1
Fuser
13
12
11
5
4
3
2
1
To J31 [2]
4
3
2
1
4
3
To J26 [1]
Input Option
Interface
Main Drive
Motor Assembly
1 2 3 4 5 6 7 8 9
10 9 8
Sensor (Input)
Sensor
(Toner Density)
Sensor
(Toner Empty)
Print Cartridge
ID Sensor
Switch
(Top Cover Interlock)
Not Used
GND
S CLK CART
S CART 3V
S DATA CART
S COV CLOSE
GND
S +5V FUSE8
Hard Drive
Cooling Fan
Sensor
(MPF Media Empty)
4
3
2
1
4
3
2
1
Print Cartridge
Cooling Fan
J93
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
4
3
2
1
(Connects to Scanner
controller card (J56)
1 2 3
3 2 1
3 2 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
GND
S TX OPT
GND
S RX OPT
3 2 1
1 2 3
3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
Toroid
12 11 10 9 8 7 6 5 4 3 2 1
Toroid
Toroid
Toroid
7
5 6
3 4
1 2
Printhead Assembly
13 12 11 10 9 8 7 6 5 4 3 2 1
5
4
3
2
1
(To Scanner Controller Card J41)
13 12 11 10 9 8 7 6 5 4 3 2 1
3 2 1
5 4 3 2 1
3 2 1
5 4 3 2 1
5 4
5 4 3 2 1
5 4 3 2 1
OP Panel USB
Port
3 2 1
J19
USB Host Port
MOD CS R
GND
MOD DIN R
GND
MOD DOUT R
GND
MOD CLK R
GND
MOD IRQ R
+5V
POR CUHD R+3.3V
+3.3V
NC MOD P6
J1
J28
GND
S DPX ENC
GND
+24V
DPX MOT -
2
FEEDBACK
J2
J29
S DPX SNS LED
S DPX SNS
GND
GND
+24vV RAW
Redrive Motor
Assembly
GND
GND
R DP3
USB DP3
USB DM3
J3
J30
+24V
S DPX FAN*
ZEROXING R*
+24V RAW
+24V RAW
+24V RAW
+24V RAW
+24V RAW
+5V
+5V
+5V
+5V
+5V
+5V
RDRV MOT+24V
RDRV MOT-24V
GND
S RDRV FEEDBACK
S RDRV FEEDBACK LED
J4
GND
USBOUT+
USBOUTGND
USBIN+
USBINGND
A0
INA RESET+5V
I2C DATA
+5V
I2C CLK
+5V
J31
GND
+24V BOT OPT
HEAT
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
+50V
J6
GND
To J32 [1]
+5V
GND
+24V
GND
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 1+CN
S +5V FUSE5
To J32 [2]
+5v
GND
LVPS
Cooling
Fan
To J22 [4]
+5V
+24vV RAW
SW2
SW1
To J22 [3]
GND
+24vV RAW
Switch
(Media size)
SW0
J32
GND
+24V TOP OPT
J26
J11
J22
S PSIZE3
GND
S PSIZE2
S PSIZE1
S TRAY1 PLOW*
GND
S +5V PLOW
S TRAY1 POUT
GND
S +5V POUT
S AC LED
S AC ENC
GND
+24V
AC MOT-
J33
J7
+24V
GND
S MAIN FAN FEEDBACK
Sensor
(Media Low)
To J26 [3]
GND
GND
+24V
GND
MM START* CN
MM LOCK* CN
MM REF CLK CN
GND
+5V SW
PH ID
HSYNC CN*
GND
J8
Sensor
(Media Empty)
J15
J16
J17
J20
J24
J27
7
6
5
4
3
2
1
TAR
DR B
To Doctor
Blade
HVPS Card Assembly
To Charge
Brush
Fuser
Lamp
CN1
CHG B
PC D DEV
To Photo
Conductor
Ground
To Toner
Add Roll
To Developer Roll
CHG
+24V
GND
S C FAN FEEDBACK
J9
J34
GND
+24V
J35
Pick Motor
Encoder
To J31 [1]
+24v HD FAN
GND
NOT USED
S MPF POUT
GND
S MPF LED
Pick Arm
Motor
To J26[4]
To Transfer Roll
To Charge Roll
MFP
TX
CLOSING
SENSOR
(FB LENGTH 3)
SENSOR
(FB LENGTH 3)
1
2
3
SENSOR
(FB LENGTH 1)
CARRIAGE DRIVE MOTOR
1
2
3
A
+24VDC
NA
B
+24VDC
NB
1
2
GND
FB_LENGTH1
+5VDC
GND
FB_LENGTH2
+5VDC
GND
1
2 FB_LENGTH3
+5VDC
3
1
2
3
4
5
6
1
GND
2
SENSOR
(ADF CLOSED INTERLOCK)
SENSOR
(ADF EXIT)
1
2
3
SENSOR
(2ND SCAN)
1
2
3
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
J1
1
2
3
INVERTER
+18 CDU
LAMP ON
GND
1
2
3
SCANNER INTERFACE CARD
CN2
CN4
SENSOR
(DOCUMENT SET)
1
2
3
SENSOR
(1ST SCAN)
1
2
3
JAM_REMOVAL
GND
+5VDC
GND
PAPER_PRES
+5VDC
+5VDC
INTERVAL
GND
+5VDC
1ST SCAN
GND
1
2
3
4
5
CN11 6
7
8
9
10
11
12
SENSOR
(ADF CLOSED INTERLOCK)
1
2
3
1
2
3
4
5
6
7
8
9
CN9
SENSOR
(ADF LOWER DOOR INTERLOCK)
1
2
3
SENSOR
(SHEET THROUGH)
1
2
3
ADF COOLING FAN
1
2
3
FAN_ON (+24VDC)
FAN_BACK
GND
1
CN12 2
3
+24V FEED
+24V FEED
NTOP FB
Cn1
ADF SOLENOID
1
2
CLOSING
GND
1
2
CN5
SCAN OUT nB
nADF INTERVAL SEN
nFLAT LENGTH 2 SEN
nHOME SEN
EXIT
GND
+5VDC
+5VDC
GND
SCAN
OPEN
GND
+5VDC
CN7
SCAN OUT nA
GND
MDC RXD
+24V FEED
+24V FEED
NTOP FB
+5V
GND
MDC RXD
NADF PRESENT SEN
GND
NADF INTERVAL SEN
NRESET
GND
I2C DAT
ADF DUPLEX
CCD ASSEMBLY
GND
+24V TP FB
GND
NTOP ADF
+5V
MDC TXD
GND
NCOVER CLOSEN SEN
NHOME SEN
GND
+3.3V
I2C CLK
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
CN8
1
2
CN4 3
4
5
6
+5V
GND
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
+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
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
+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
1
2
CN3 3
4
5
6
J1
NB
+24VDC
B
NA
+24VDC
A
NB
+24VDC
B
NA
+24VDC
A
Cn3
Cn6
Cn3
FEEDBACK
GND
+5V
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
1
2
3
1
2
1
2
3
FB ARROW
LED
SCANNER
COOLING
FAN
SENSOR
(SCANNER HP)
+18V CDU
ADF LAMP ON
GND
ADF SCK R
ADF SHR R
+5 CDU
ADF LVDS R TXOUT0+
ADF LVDS R TXOUT1+
ADF LVDS R TXOUT+2
GND
ADF LVDS R NCLK-
FEEDBACK
GND
+5V
+5V
FB LED ON
CN2
1
2
3
1
2
1
2
3
MOTOR
(ADF FEED)
MOTOR
(ADF TRANSPORT)
GND
ADF LVDS R NCLK+
GNDGND
ADF LVDS R TXCLK+
GNDGND
ADF LVDS R TXOUT2GNDGND
ADF LVDS R TXOUT1GNDGND
ADF LVDS R TXOUT0GNDGND
ADF AFE RESET R
ADF SDI R
ADF SEN R
ADF POWER SAVE CONTR
+5VCDUGND
+18V CDU
GND
1
2
3
4
5
6
1
2
3
4
5
6
GND
ADF LVDS R NCLK+
GNDGND
ADF LVDS R TXCLK-ADF LVDS R TXCLK+
GNDGND
ADF LVDS R TXOUT2GNDGND
ADF LVDS R TXOUT1GNDGND
ADF LVDS R TXOUT0GNDGND
ADF AFE RESET R
ADF SDI R
ADF SEN R
ADF POWER SAVE CONTR
+5VCDUGND
+18V CDU
GND
GND
+24V TP FB
GND
NTOP ADF
+5V
MDC TXD
GND
NCOVER CLOSEN SEN
NHOME SEN
GND
+3.3V
I2C CLK
STANDARD BIN LED
1
2
3
4
+24V FEED
+24V FEED
NTOP FB
+5V
GND
MDC RXD
NADF PRESENT SEN
GND
NADF INTERVAL SEN
NRESET
GND
I2C DAT
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
+18V CDU
ADF LAMP ON
GND
ADF SCK R
ADF SHR R
+5 CDU
ADF LVDS R TXOUT0+
ADF LVDS R TXOUT1+
ADF LVDS R TXOUT+2
GND
ADF LVDS R NCLK-
J42
(Connects to System Card JFX2)
J41
J56
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
J15
nUICC M RESET
LVDS Tx1LVDS Tx2LVDS CLK TXGND
UI TXD
LVDS T0GND
+5V LED BL
SCANNER CONTROLLER
CARD
(Connects to System Card JFX1)
J11(DUPLEX ADF ONLY)
J1
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
J2
+5VDC
LED On
LED DIM
GND
1
2
3
4
Cn2
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
GND
FB LAMP ON
+18V CDU
+18V CDU
GND
+5V CDU
+5V CDU
FB POWER SAVE CONTR
FB SHR R
FB SEN R
FB SCK R
FB SDI R
GND
FB AFE RESET R
GND
FB LVDS R TXOUT0+
FB LVDS R TXOUT0GND
FB LVDS R TXOUT1+
FB LVDS R TXOUT1GND
FB LVDS R TXOUT2+
FB LVDS R TXOUT2GND
FB LVDS R TXCLK+
FB LVDS R TXCLKGND
FB LVDS R NCLK+
FB LVDS R NCLKGND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
ADF Controller
Card
1 2 3 4 5
6 7 8 9 10
+24V RAW
+5V
1
2
3
4
5
6
7
8
GND
+5V
GND
DIDTH1
WIDTH2
GND
LENGTH
+5VDC
+5VDC
LED_ON
GND
+5V
SENSOR (ADF PAPER
WIDTH)
1
2
3
1
2
3
SENSOR
(ADF PAPER LENGTH)
1
2
LED
(PAPER PRESENT)
+24V RAW
GND
J6
SCANNER CCD ASSEMBLY
+24V RAW
GND
GND
LVDS TX+1
LVDS TX+2
LVDS CLK TX+
+5V
UI RXD
LVDS Tx0+
+5V
+5 LED BL
1
2
3
(Connects to System
Card J10)
LCD
GND
LCD PWM DIM
3.3VDC 3.3VDC
3.3VDC 3.3VDC
LCD ENABLEGND
GND
LCD B5LCD B4
LCD B3
LCD B2LCD B1
LCD B0
LCD G5LCD G4
LCD G3
LCD G2
LCD G0
LCD R5
LCD R3GND
LCD R2
LCD RO
GND
GND
4
3
2
1
1
2
3
LCD R1
GND
LCD CLK
GND
GND
LCD G1
GND
LCD R4
GND
GND
GND
GND
3.3VDC
Y+
X+
YX-
INVERTER
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
37 38
39 40
+18 CDU
LAMP ON
GND
TOUCH PANEL
CN1
nUICC M RESET
LVDS Tx1LVDS Tx2LVDS CLK TXGND
UI TXD
LVDS T0GND
+5V LED BL
GND
LVDS TX+1
LVDS TX+2
LVDS CLK TX+
+5V
UI RXD
LVDS Tx0+
+5V
+5 LED BL
4
3
2
1
J3
J10
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
1 2
3 4
5 6
7 8
9 10
11 12
13 14
15 16
17 18
19 20
21 22
23 24
25 26
27 28
29 30
31 32
33 34
35 36
37 38
39 40
J14
GND
LCD PWM DIM
3.3VDC 3.3VDC
3.3VDC 3.3VDC
LCD ENABLEGND
GND
LCD B5LCD B4
LCD B3
LCD B2LCD B1
LCD B0
LCD G5LCD G4
LCD G3
LCD G2
LCD G0
LCD R5
LCD R3GND
LCD R2
LCD RO
GND
GND
UICC
LCD R1
GND
LCD CLK
GND
GND
LCD G1
GND
LCD R4
GND
GND
GND
GND
3.3VDC
MFP SCANNER/ADF