Dell Multifunction Laser Printer 5535dn- User Manual

vi Service Manual Menu Settings Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25 EVENT LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

Table of contents vii Pick arm assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47Switch (media size) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-...

viii Service Manual Document scanning at platen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68 Names and functions of components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68 Sc...

Table of contents ix Repair information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Handling ESD-sensitive parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

Table of contents xi Cover, right rear corner removal (model X658) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88Sensor (standard bin exit) actuator assembly removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89Sensor (ADF media exit) bracke...

xii Service Manual Sensor (scanner HP) assembly w/bracket removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154LVPS cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154 Option removal...

Table of contents xiii MFP stapler assembly sensor (media stack) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-215MFP stapler assembly sensor (paddle HP) removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-215MFP stapler assembly sensor (staple...

xiv Service Manual Parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 How to use this parts catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

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 conformi...

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 n...

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...

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 pro...

Lithium warning 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 b...

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 ...

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 prod...

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 repair it. Special tools and test equipment, as well as general environmenta...

General information 1-1 1. General information allows the user to adjust the viewing angle. The Dell™ 5535dn printer is an All-In-One laser multi-functional printer (MFP) that provides print, copy, scan, determine the MPF problem and repair the failure. After you complete the repair, perform tests a...

1-2 Service Manual 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. Note: Printer configuration may vary depending on your printer model. Basic models 1 Automatic Document Fee...

General information 1-3 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...

1-4 Service Manual 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 Paper size D...

General information 1-5 Paper types and weights supported by the printer 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 par...

Tools required for service Flat-blade screwdrivers, various sizesPhillips screwdrivers, various sizes7/32 inch open-end wrench7.0 mm nut driver5.5 mm wrenchNeedlenose pliersDiagonal side cuttersSpring hookAnalog or digital multimeterFlash light (optional) General information 1-7

Acronyms ADF Automatic Document Feeder AIO All-In-One CCD Charge Coupled Device (CCD) CRU Customer Replaceable Unit DIMM Dual Inline Memory Module DRAM Dynamic Random Access Memory EP Electrophotographic process EPROM Erasable Programmable Read-Only Memory ESD Electrostatic Discharge FRU Field Repla...

Diagnostic information 2-1 2. Diagnostic information Start 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 erro...

2-2 Service Manual 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 po...

Diagnostic information 2-3 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...

Diagnostic information 2-11 Error code table Error code or message Error contents Description/Action Possible repair actions 200.00 Sensor (input) area jam The media is jammed in the sensor (input) area. 1. Fan the media and check for obstructions. 2. Go to sensor (input) service check. 200.01 Senso...

Diagnostic information 2-107 Service checks Sensor (input) service check Sensor (fuser output) service check Step Check Yes No 1 Check the sensor (input) for damage. Is the above component free from damage? Go to step 2. Replace the sensor (input). 2 1. Enter the diagnostic mode 2. Select Base senso...

Diagnostic information 2-111 Switch (ADF closed interlock) jam service check Step Check Yes No 1 1. Enter the diagnostic mode 2. Select Scanner tests 3. Select Sensor tests 4. Observe the line item “sensor (ADF closed interlock)” Does the display on the operator panel, change every time the sensing ...

2-112 Service Manual Sensor (ADF sheet through) static jam service check Use this procedure for the following jams: • 290.00 1 Check the media path. Is the media path free of media or media fragments? Go to step 2. Remove any media or media fragments. 2 Check the sensor (ADF sheet through) for prope...

2-114 Service Manual Sensor (ADF 1st scan) late jam service check 6 Check the sensor (ADF sheet through) for proper connection. Is the above component properly connected? Replace the sensor (ADF sheet through). Replace the connection. 7 Place an undamaged document in the ADF, and perform a ADF test....

Diagnostic information 2-115 Sensor (ADF sheet through) lingering jam service check 4 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 scan)” Does the display on the operator panel,...

Diagnostic information 2-117 Sensor (1st scan) static jam service check Use this procedure for the following jams: • 290.10 1 Check the media path. Is the media path free of media or media fragments? Go to step 2. Remove any media or media fragments. 2 Check the sensor (ADF 1st scan) for proper oper...

Diagnostic information 2-119 Sensor (ADF media exit) late jam service check 2 Check the original document condition. Is the original document free of paper clips and staples as well as damage such as creases, tears, holes or excessive wear? Go to step 3. Remove damaged original document and replace ...

2-122 Service Manual Sensor (ADF media exit) static jam service check 2 Check the sensor (ADF document set) for proper operation. 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 th...

Diagnostic information 2-125 Sensor (ADF media exit) lingering jam service check Use this procedure for the following jams: • 294.03 Step Check Yes No 1 Check the original document condition. Is the original document free of paper clips and staples as well as damage such as creases, tears, holes or ...

Diagnostic information 2-129 18 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. The sensor...

2-132 Service Manual Step Check Yes No 1 Check the media path for partially fed or jammed media. Is the media path free from partially fed or jammed media? Go to step 2. Remove any pre-staged or jammed media. 2 Check the sensor (input) for proper operation. 1. Enter the diagnostic mode 2. Select Bas...

Diagnostic information 2-133 6 Check the above sensor for proper connection. Is the above sensor connected properly? Replace the fuser unit assembly. Replace the connection. 7 Check the aligner assembly for obstructions. Is the above component free from obstructions? Go to step 8. Remove obstruction...

2-136 Service Manual Sensor (narrow media) static jam service check 5 Check the sensor (narrow media) 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 abo...

Diagnostic information 2-137 2 Check the sensor (narrow media) 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. Go t...

Diagnostic information 2-139 Use this procedure for the following jams: • 230.01 • 230.05 • 232.00 Step Check Yes No 1 Check media origination. Did the media originate from the internal duplex? Go to step 2 Go to step 7 2 Check the internal duplex media path for obstructions. Is the above component ...

2-140 Service Manual 10 Perform a print test using the duplex. Does the problem remain? Contact next highest level of tech support. Problem solved. Use this procedure for the following jams: • 230.13 • 238.01 • 238.03 • 238.05 • 238.07 Step Check Yes No 1 Check media origination. Did the media origi...

Diagnostic information 2-141 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 • 2...

2-142 Service Manual 8 Perform a print test and check the pick arm assembly for the appropriate media tray. Is the media properly picked and advanced out of the Go to step 8. Replace the appropriate pick arm assembly. 9 Perform a print test and check the main motor assembly. Is the media properly tr...

Diagnostic information 2-143 Sensor (pass through) static jam service check 4 Check the above sensor for proper connection. Is the above sensor connected properly? Replace the appropriate Sensor (pass through). Replace the connection. 5 Perform a print test and check the main motor assembly. Is the ...

2-148 Service Manual Sensor (mailbox empty) static jam service check 2 Check for obstructions in the media path between the Sensor (mailbox empty) machine and the media bin. Is the media path free from obstructions? Go to step 3. Remove obstructions. 3 Check the sensor (mailbox empty) for proper ope...

Diagnostic information 2-149 Sensor (toner empty) service check Sensor (scanner HP) service check Sensor (ADF 2nd scan) late jam service check Step Check Yes No 1 Check the sensor (toner empty) for proper installation. Is the above component properly installed? go to step 2. Reinstall the sensor (to...

Diagnostic information 2-151 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 • Note: When horizontal lines and/or spots occur periodically, it is possibly caused b...

2-152 Service Manual Image Quality Faint print (Low contrast) Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step Check Yes No 1 Check the media condition. Load new, dry, recommended media, and perform a print test. Is the image den...

2-156 Service Manual Solid black Check the media path for foreign objects such as staples, clips, scraps of media. Step Check Yes No 1 Check the charge roll assembly for proper installation. Is the above component properly installed? Go to step 2. Replace the charge roll assembly. 2 Check the print ...

Diagnostic information 2-157 Vertical lines and bands (process direction) Step Check Yes No 1 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Go to step 2. Problem solved. 2 Is the media transfer route and the media path clear of de...

2-158 Service Manual Horizontal white stripes or bands (side to side direction) Step Check Yes No 1 Check the media condition. Load new, dry, and recommended media. Re-print the defective image. Does the error continue? Go to step 2. Problem solved. 2 Are the media transfer route and the media path ...

2-160 Service Manual Horizontal stripes (side to side direction) 7 Perform a print test. Does the problem remain? Contact next highest level of tech support. Problem solved. Step Check Yes No 1 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the error ...

2-162 Service Manual Partial lack Step Check Yes No 1 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the problem remain? Go to step 2. Problem solved. 2 Check the toner level. Is the toner level normal? Go to step 3. Replace the print cartridge. 3 Che...

Diagnostic information 2-163 Spots Step Check Yes No 1 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Go to step 2. Problem solved. 2 Check the media transfer route. Is the media route free of contamination or debris? Go to step 3....

Diagnostic information 2-165 After image The ghost appears on the media which, may be the image from the previous page or part of the page currently printing. Step Check Yes No 1 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the error continue? Go to...

Diagnostic information 2-167 Skew The printed image is not paralleled with both sides of the media. Step Check Yes No 1 Check printer installation placement. Check the installation surface for irregularities. Check for damaged printer caster. Is the setup surface normal? Go to step 2. Correct the in...

2-168 Service Manual Media damage Step Check Yes No 1 Check printer installation placement. Check the installation surface for irregularities. Check for missing printer foot. Is the setup surface normal? Go to step 2. Correct the installation placement. 2 Check the media feed. Remove the media tray ...

2-170 Service Manual No fuse Step Check Yes No 1 Check the fuser unit assembly installation. Is the fuser unit assembly properly installed? Go to step 2. Reinstall the fuser unit assembly. 2 Check the media condition. Load new, dry, recommended media. Re-print the defective image. Does the problem r...

Diagnostic information 2-171 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: • Note: When horizontal lines and/or spots occur periodically, it is possibly caused by a particu...

2-172 Service Manual ADF & Scanner Image Quality Dark image quality (using ADF or Scanner) Before starting, check the media route for foreign objects, such as staples, clips, and scraps, in the media path. Step Check Yes No 1 Check the large and small platen glass on the scanner unit assembly. I...

Diagnostic information 2-173 Vertical lines (process direction using the ADF) Step Check Yes No 1 Check the small platen glass on the scanner unit assembly. Is the large and small platen glass contaminated or damaged? Clean or replace the scanner platen glass cover. Go to step 2. 2 Check the three m...

2-178 Service Manual 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 sett...

Diagnostic aids 3-1 3. Diagnostic aids Understanding the printer control panel Item Description 1 Display View scanning, copying, faxing, and printing options as well as status and error messages. 2 Keypad Enter numbers or symbols on the display. 3 Dial Pause • Press to cause a two- or three-second ...

3-2 Service Manual 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...

3-4 Service Manual 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 anoth...

Diagnostic aids 3-5 Other touch-screen buttons Right arrow Scrolls right Submit Saves a value as the new user default setting Back Navigates back to the previous screen Button Function Down arrow Moves down to the next screen Up arrow Moves up to the next screen Unselected radio button This is an un...

Diagnostic aids 3-7 Accessing service menus There are different test menus that can be accessed during POR to identify problems with the printer. Diagnostics Menu 1. Turn off the printer.2. Press and hold the 3 and 6 buttons simultaneously for about 10 seconds. 3. Turn on the printer.4. Release the ...

3-8 Service Manual Diagnostics Menu Entering Diagnostics Menu 1. Turn off the printer. 2. Press and hold 3 and 6 buttons simultaneously. 3. Turn on the printer. 4. Release the buttons after 10 seconds. Available tests The tests display on the operator panel in the order shown: Note: Some menus are n...

3-10 Service Manual 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. PRINTER SETUP EP SETUP REPORTS EVENT LOG SCANNER TESTS Diagnostics Menu tests (Continued) Exit Diag Menu Defaults See “Default...

3-12 Service Manual 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 th...

Diagnostic aids 3-13 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 ...

3-14 Service Manual 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. • Confi...

Diagnostic aids 3-15 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...

3-16 Service Manual 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 . To stop testing before completion, turn the printer off. DUPLEX TESTS Quick Test (duplex) This ...

Diagnostic aids 3-17 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 To set the Top Margin (duplex): 1....

3-18 Service Manual 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. ...

Diagnostic aids 3-19 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 lo...

3-20 Service Manual 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 envelop...

Diagnostic aids 3-21 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 d...

3-22 Service Manual PRINTER SETUP 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 printe...

Diagnostic aids 3-23 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...

3-24 Service Manual EP SETUP 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 se...

3-26 Service Manual 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 ...

Diagnostic aids 3-27 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 u...

Diagnostic aids 3-29 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. Maintenance Counter Value The current value for the maintenance page counter is displayed. This counter tracks printe...

3-30 Service Manual 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...

Diagnostic aids 3-31 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: Touch Back to return to the Configuration Menu. Event Log The event log provides...

3-32 Service Manual 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 ch...

Diagnostic aids 3-33 Factory Defaults This setting enables a user to restore all the printer settings to the original factory settings. Selections are Embedded Solutions applications (LES). Network does not appear unless you have a network printer. The following settings are not changed: • Display l...

3-34 Service Manual 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...

Diagnostic aids 3-35 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 wil...

3-36 Service Manual 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 ...

Diagnostic aids 3-37 Touch Back to exit without changing the value. Action for Prompts 1. Touch to select Action for Prompts from the Configuration Menu. The panel displays the setting's name in the header and [ setting's current value ] below the header row. 2. Touch or to change the value. The val...

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

3-42 Service Manual Printer configurations Note: Printer configuration may vary depending on your printer model. Basic models 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 ...

Diagnostic aids 3-43 Printer theory PC cartridge Sensor (input) PC drum Standard bin full actuatorand sensor (standard bin full) Diverter Sensor(duplex input) Sensor (fuser output)Sensor (narrow media) Pick armassembly Sensor (optionpass through) Models X651, X652/5535dn, X654, and X656 paper path r...

3-44 Service Manual Model X658 paper path rolls and sensors 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...

Diagnostic aids 3-45 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 m...

3-46 Service Manual Media tray assembly Wear strips Side guides End guides

Diagnostic aids 3-47 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...

3-48 Service Manual 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...

Diagnostic aids 3-51 Registration 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...

3-52 Service Manual Transfer 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 medi...

Diagnostic aids 3-53 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. 1. LD card assembly — generates the laser beam...

3-54 Service Manual Conceptual diagram of an image created by scanning Fuser Fuser unit assembly

Diagnostic aids 3-55 Fuser components Heat roll The heat roll is a hollow metal tube with a coated surface. This tube is heated by the inner heater lamp. The heat is applied to the media passing between the heat roll and pressure roll, fusing the toner on the media.

3-56 Service Manual 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...

Diagnostic aids 3-57 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. Type 2...

3-58 Service Manual 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 ...

Diagnostic aids 3-59 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. Electrical components and controller Switch (printer front door interlock) Redrive motorassembly Main drivemotor ass...

Diagnostic aids 3-61 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 c...

3-62 Service Manual 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

Diagnostic aids 3-63 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...

3-64 Service Manual This discharge/no discharge process creates an invisible, electrostatic image on the surface of the drum. This image is called a latent image. Development The toner contained within the PC Cartridge has an electrical property that causes it to adhere to the development roll. The ...

3-66 Service Manual negative electrical charge of the inner conductive layer of the drum and the positive electrical charge of the paper. Cleaning The Cleaning Blade removes any toner that remains on the drum after the transfer process. The toner that the Cleaning Blade removes is collected inside t...

Diagnostic aids 3-67 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 ...

3-68 Service Manual Document scanning at ADF The document scanning section of this machine consists of a scanner that reads a single-sheet document placed on the platen glass and a document feeder that can transport a multiple-sheet document for one or two-sided scanning. Document scanning at platen...

Diagnostic aids 3-69 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 preven...

3-70 Service Manual Shown below is the document feed path from the ADF. 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...

Diagnostic aids 3-71 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. Names and functions of components ADF Sensor (ADF long media) The document length in the slow ...

3-72 Service Manual 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 ...

Diagnostic aids 3-73 This solenoid causes the ADF pick roll to be raised and lowered in order to properly pick the media. Switch (ADFclosed interlock) Sensor (Media exit) Sensor (ADF lowerdoor interlock) Sensor (ADF document set) Sensor (ADF front registration) Sensor (ADF rear registration) Sensor ...

3-74 Service Manual High Capacity Input Tray (HCIT) tray assembly Rear media tray guide Media end guide Pick armassembly Sensor (media empty) Sensor (media low) Media sizeactuator Sensor(pass through) HCF drawerassembly Sensor(tray raised HP) Tray lift drive motor

Diagnostic aids 3-75 250-sheet/550-sheet tray assembly 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 finge...

3-76 Service Manual 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 th...

Diagnostic aids 3-77 Pick arm assembly Sensor (media empty) Sensor (media low) 250-sheet drawer assembly Sensor (pass through) Pick arm assembly Sensor (media empty) Sensor (media low) 550-sheet drawer assembly Sensor (pass through)

3-78 Service Manual 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. PC cartridge Sensor (input) PC drum Standard bin full actuatorand sensor (standard bin full) Diverte...

3-82 Service Manual 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 remai...

Diagnostic aids 3-83 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 followi...

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

3-88 Service Manual 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....

Diagnostic aids 3-89 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 t...

3-92 Service Manual 4. Open the scanner cover, and then remove any jammed pages. 5. Open the bottom ADF door, and then remove any jammed pages. 6. Close the bottom ADF door and scanner cover. 7. Touch Restart Job . 1 2

Diagnostic aids 3-93 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,...

3-94 Service Manual Flatbed scanner skew adjustment 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). ADF skew adjustment (via ADF document tray) 2. Loosen the screws securing the ADF document tray on...

3-96 Service Manual ADF skew adjustment (Via duplex CCD assembly) 1. Remove the ADF cover, front. Go to “ADF cover, front removal” on page 4-64 .

3-98 Service Manual Media squareness check This test is critical when cut paper is being used to align the ADF skew during reworks. Pallets of quality paper may be found with more than 2 mm of skew. 1. Remove two consecutive pieces of paper from the ream. 2. Flip one of the pages over in the directi...

3-100 Service Manual 5. Look closely at the top edge of the media to see if the sheets are aligned. Square Media: Top and sidesare perfectly aligned The two pages do not align perfectly at the top or sides. Media Not square: use for ADF skew rework. DO NOT

Diagnostic aids 3-101 Print skew correction procedure 1. Check the paper squareness. 2. Make sure the guides in the paper tray are properly aligned. 3. Check the base printer skew and registration. 4. Plug printer into the power source and power on in Diagnostics Mode (hold down 3 and 6 during POR) ...

3-102 Service Manual 7. Determine if the printer passes or fails the skew specifications based on the values listed on the table.. 9. Check the registration by looking at the dots at the edges of the page. Adjust as needed. Skew Specification (L2-L1) (R2-R1) (T2-T1) (B2-B1) Letter 1.4 mm 1.4 mm 1 mm...

Diagnostic aids 3-103 Copy skew correction procedure Note: This specification is used for copies from the flatbed, front ADF, and back ADF. 1. Check the paper squareness. 2. Make sure the guides in the paper tray are properly aligned. 3. Check the printer skew and registration. 4. Make sure the page...

Diagnostic aids 3-105 Security Reset Jumper 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 eac...

3-106 Service Manual 3. Remove the small yellow jumper that covers a pair of the jumper’s pins. 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: Th...

Diagnostic aids 3-107 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 aligne...

3-108 Service Manual 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 scanTop print position accuracy (feeding direction): +/-0.5 mm - start on scanHorizontal page width accuracy:...

Repair information 4-1 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 inst...

4-2 Service Manual 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 printh...

Repair information 4-3 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 repl...

4-4 Service Manual 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 housi...

Repair information 4-5 Removal procedures Before starting service work 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 ...

4-6 Service Manual 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 fro...

Repair information 4-7 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. 3. Remove the four screws (A) securing the duplex assembly to the machine.4....

4-8 Service Manual Duplex cooling fan removal 2. Remove the screw (A) securing the duplex cooling fan to the machine.3. Disconnect the connector (B) from the duplex cooling fan. 4. Remove the duplex cooling fan. Replacement Warning: When replacing the duplex cooling fan, ensure that it is installed ...

Repair information 4-9 Duplex drive motor assembly removal 3. Remove the three screws (A) securing the duplex drive motor assembly to the machine. Note: When removing the duplex drive motor assembly, the upper duplex drive belt (B) will become detached. 4. Remove the band (C) from the duplex drive m...

4-10 Service Manual 7. Remove the harness (E) from the duplex drive motor assembly. Replacement Warning: When replacing the duplex drive motor assembly, ensure that all harnesses are properly re-routed. Replacement Note: Ensure the belt is replaced properly. Duplex input sensor assembly removal 1. R...

4-12 Service Manual Media turn guide removal 2. Gently bend the left side of the media turn guide to release the hook (A) as shown in the picture. 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...

4-14 Service Manual Main cooling fan removal 2. Remove the six screws (A) securing the metal shield to the machine. 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 coolin...

Repair information 4-15 7. Remove the fuser cooling fan connection (C). Fuser drive release linkage removal 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 fro...

4-16 Service Manual 5. While pressing the two buttons (A), pull the fuser unit assembly from the machine. Replacement Warning: When replacing the fuser unit assembly, ensure that the electrical connection (B) and the two buttons (A) are properly secured. Fuser wiper cover assembly removal 1. Press t...

Repair information 4-17 HVPS card assembly removal 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. Replacement Warning: When replacing the HVPS...

4-18 Service Manual 2. Release the two hooks (A) securing the lower portion of the inner deflector to the machine. 3. Remove the inner deflector. Replacement Warning: When replacing the inner deflector, ensure that it is properly installed, or jamming will occur. Option drive shaft removal 1. Gently...

4-20 Service Manual Main drive motor assembly removal 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. Repl...

Repair information 4-21 Alignment assembly removal WARNING: When replacing the alignment assembly, ensure that the media skew is properly adjusted using 2. Remove the six screws (A) securing the metal cover to the machine. 3. Remove the metal cover. A the adjuster screw (C), or jamming will occur. S...

4-22 Service Manual 6. Remove the two screws (B) securing the alignment assembly to the machine. Note: The adjuster screw (C) requires a hex wrench to loosen and tighten. Note: The adjuster screw (C) can be accessed through the hole (D) in the system card. 7. Completely loosen the adjuster screw (C)...

Repair information 4-23 Media out actuator removal 2. Release the hook (A) securing the media out actuator to the unit. 3. Remove the media out actuator. Media support removal 1. Gently detach the two bosses (A) of the media support from the machine. 2. Remove the media support. A A A 1. Remove the ...

4-24 Service Manual Tray roller catch assembly removal 1. Remove the media tray. 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 2. Release the ...

Repair information 4-25 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. 5. Remove the MPF lift plate assembly. Replacement Warning: When replacing the...

4-26 Service Manual MPF pick roll assembly removal 2. Remove the E-clip (A) securing the MPF print roll assembly to the machine.3. Remove the plastic washer (B). 4. Remove the MPF pick roll assembly. Replacement Warning: When replacing the MPF pick roll assembly, do not touch the rubber surface. MPF...

Repair information 4-29 Pick arm assembly removal 1. Remove the media tray from the machine.2. Place the machine on the left or right side.3. Remove the spring (A).4. Remove the two E-clips (B) securing the pick arm assembly to the machine. B A

Repair information 4-31 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. 3. Remove the two pick roll assemblies. Replacement Warning: When replacing the pick roll assembly, do not touch...

4-32 Service Manual Print cartridge clamp assembly removal Note: This procedure can be applied to the left or right printer cartridge hold down assembly. 2. Remove the screw (A) securing the print cartridge clamp assembly to the machine. 3. Remove the print cartridge clamp assembly. A X656)” on page...

Repair information 4-33 Print cartridge ID connector assembly removal 1. Remove the print cartridge. 3. Release the two hooks (A) securing the print cartridge ID connector assembly to the machine. 4. Remove the print cartridge ID connector assembly.5. Disconnect the connection (B) from the print car...

4-34 Service Manual Printhead assembly removal WARNING: When replacing the printhead assembly, ensure that the printhead skew is properly adjusted, or 2. Remove the six screws (A) securing the metal cover to the machine. 3. Remove the metal cover.4. Disconnect the connections (B) from the printhead ...

Repair information 4-35 5. Remove the four screws (C) securing the printhead assembly to the machine. 6. Remove the printhead assembly. Replacement Warning: When replacing the printhead assembly, ensure that the printhead skew is properly Connection access cover, rear removal 1. Gently detach the tw...

4-36 Service Manual 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....

4-38 Service Manual 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. 3. Remove the cover assembly, rear lower. Redrive motor assembly removal 2. Remove the six screws (A) securing the m...

Repair information 4-41 Sensor (duplex input) removal 2. Release the hooks (A) securing the senor (duplex media path) to the bracket. 3. Remove the sensor (duplex input). Sensor (media low) removal 2. Release the hooks (A) securing the sensor (media low) to the assembly. 3. Remove the sensor (media ...

4-42 Service Manual 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 2. Release the hooks (A) securing the sensor (input) to the machine. 3. Remove the se...

4-44 Service Manual Standard bin actuator assembly removal 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 r...

Repair information 4-45 Sensor (toner density) removal 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 2. Remove the six screws (A...

Repair information 4-47 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. 3. Disconnect the connector (A) from the LVPS card assembly.4. Remove the two screws (B) from the LVPS card ...

Repair information 4-49 Access door removal 1. Open the access door.2. Gently detach the two hinges (A) of the access door from the machine. 3. Remove the access door. A

4-50 Service Manual System card assembly removal 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 ...

Repair information 4-53 Hard drive removal 2. Loosen the two screws (A) securing the hard drive to the rear of the machine. 3. Remove the system card metal plate. 4. Gently detatch the hard drive from the system card. 5. Disconnect the connector from the system card. A Hard drive connector 1. Remove...

4-54 Service Manual Hard drive cooling fan removal 2. Remove the system card metal plate. 3. Loosen the five screws securing the fan mounting bracket to the machine. 4. Remove the fan mounting bracket. 5. Remove the two screws (A) securing the hard drive cooling fan to the fan mounting bracket. 6. R...

Repair information 4-55 Fax card assembly removal 2. Remove the system card metal plate. 3. Loosen the two screws (A) securing the fax card assembly to the rear of the machine. 4. Gently detatch the fax card assembly from the machine. 5. Disconnection the connection from the system card. A Fax conne...

4-56 Service Manual 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 ...

Repair information 4-57 Transfer roll bracket assembly, left removal 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 bu...

Repair information 4-59 Transfer deflector removal 2. Gently unsnap the transfer deflector from the machine.3. Remove the transfer deflector.4. Remove the screw (A) securing the ground wire to the transfer deflector. 5. Remove the ground wire. Replacement Warning: When replacing the transfer deflect...

4-60 Service Manual Redrive assembly removal 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. ...

Repair information 4-61 ADF feed / pick roll assembly removal 1. Lift the ADF top door assembly. 2. Slide the ADF pick roll assembly to the front. 3. Lift the rear of the ADF pick roll assembly. 4. Remove the ADF pick roll assembly. Rear Right Front Left

4-62 Service Manual ADF separator roll removal 1. Lift the ADF top door assembly. 3. Remove the access cover. 4. Press tab (A), and slide the separator roll off the shaft. A 2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61 .

Repair information 4-63 ADF separator torque limiter assembly removal 1. Lift the ADF top door assembly. 3. Remove the access cover. 4. Press tab (A), and slide the separator roll off the shaft. A 2. Remove the ADF feed / pick roll assembly. See “ADF feed / pick roll assembly removal” on page 4-61 .

4-64 Service Manual 5. Slide the ADF separator torque limiter assembly to the front, and remove. ADF cover, front removal 1. Lift the ADF top door assembly. 2. Remove two screws (A) from the top of the front cover assembly. 3. Remove one screw (B) from the bottom of the ADF cover, front. 4. Release ...

Repair information 4-65 ADF cover, rear removal 1. Lift the ADF left door cover. 2. Remove two metal screws (A). 3. Remove the plastic screw (B) from the right side of the ADF cover, rear. 4. Remove the ADF cover, rear. ADF document tray assembly removal 3. Remove the two metal screws (A) from the t...

4-66 Service Manual ADF top door assembly removal 3. Lift the ADF top door assembly. 4. Push down on the spring clips (A) on the left and right sides. 5. Remove the ADF left door links (B). 6. Unscrew the two hinge pins (C) on the left and right side. C C B A 1. Remove the ADF cover, front. See “ADF...

Repair information 4-67 7. Pry out the front tabs (D). 8. Remove the ADF top door assembly. ADF controller card removal 2. Disconnect all cables attached to the controller card. 3. Remove the four screws (A) securing the ADF controller card. 4. Remove the ADF controller card. D 1. Remove the ADF cov...

4-68 Service Manual 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 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 scre...

4-70 Service Manual 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 p...

4-72 Service Manual ADF pinch roll assembly removal 2. Remove the two screws (A) on either side of the ADF pinch roll assembly. 3. Remove the ADF pinch roll assembly. A 1. Remove the ADF top door assembly. See “ADF top door assembly removal” on page 4-66 .

Repair information 4-73 ADF turn guide removal 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. Note: Upon reassem...

4-74 Service Manual 5. Pivot the turn guide out from the front side, giving room to dislodge the locating pins (B) from the rear. 6. Remove the ADF turn guide. ADF media pinch pad assembly removal A B 1. Remove the ADF duplex CCD assembly. See “ADF duplex CCD assembly removal (X654, X656, and X658)”...

Repair information 4-77 ADF transport drive motor bracket assembly w/cable removal 2. Remove the ADF transport drive motor bracket tension spring (A). 3. Remove the wires from the retaining clip (B) on top of the bracket. 4. Disconnect the ADF transport drive motor harness. 5. Remove the two screws ...

Repair information 4-79 ADF pick roll position cam assembly removal 3. Disengage the clip (A) on the shaft arm (B), securing it to the shaft. 4. Remove the two springs attached to the shaft arm (B). 5. Remove the three screws (C) securing the ADF pick roll position cam assembly bracket. 6. Remove th...

4-80 Service Manual ADF solenoid assembly removal 2. Remove the pick roll position cam assembly spring from the cam shaft lever. 3. Disconnect the solenoid wire harness. 4. Remove the two screws (A) securing the solenoid bracket assembly to the frame of the ADF unit assembly. 5. Remove the ADF solen...

Repair information 4-81 Sensor (ADF lower door interlock) removal 3. Open the bottom door assembly. 4. Remove the sensor by squeezing the tabs (A) and removing it from the front of the ADF frame. 5. Disconnect the lower sensor (ADF lower door interlock) harness. 6. Remove the sensor (ADF lower door ...

Repair information 4-83 Sensor (ADF document set) removal 2. Remove the three screws (A) securing the separator guide to the ADF frame. 3. Remove the sensor (ADF document set) harness. 4. Remove the two screws (B) securing the sensor (ADF document set) bracket to the ADF frame. 5. Remove the sensor ...

Repair information 4-85 3. Slide the left scanner cover to the rear, and remove. 4. Disconnect the CCD harness and ground strap from behind the left side scanner cover. 5. Disconnect the CCD harness and ground strap from behind the rear scanner cover. 6. Open the ADF. 7. Remove the two thumb screws ...

4-86 Service Manual 6. Remove the two thumb screws (A) on both sides of the ADF unit. 7. Slide ADF unit to the rear, lift up, and remove the ADF unit assembly. ADF left hinge removal A Replacement note: You must adjust skew after reinstalling the ADF unit assembly. Go to “Adjusting skew” on page 3-9...

Repair information 4-87 3. Remove the screw (A). 4. Remove the ADF left hinge. 3. Remove the four screws (A) securing the ADF right hinge to the ADF unit assembly. 4. Remove the ADF right hinge. A A 2. Remove the ADF cover, rear assembly. See “ADF cover, rear removal” on page 4-65 . ADF right hinge ...

4-88 Service Manual Cover, left rear corner removal (model X658) 2. Remove the two screws (A) securing the cover, left rear corner to the machine. 3. Slide the cover, left rear corner up and out. Cover, right rear corner removal (model X658) 2. Open the rear door. A 1. Remove the scanner support cov...

Repair information 4-89 3. Remove the two screws (A) securing the cover, right rear corner. 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. A X654, and X656)” on page 4-103 or “Redriv...

Repair information 4-91 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. R...

Repair information 4-93 Scanner reference LED cable assembly removal 2. Remove the screw (A) securing the scanner reference LED cable assembly to the flatbed frame. 3. Remove the scanner reference LED cable assembly. 4. Remove the wire harness from the scanner reference LED cable assembly. A 1. Remo...

4-96 Service Manual 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 repla...

Repair information 4-99 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. 3. Remove the two retaining clips (A) from the hinges on the MPF tray door. 2. Remove the MPF media guide assembly. See “MP...

Repair information 4-101 Fuser access assembly removal 2. Pull the fuser access assembly out to remove. 1. Open the door assembly, rear. 1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124 . Note: If you do not have a short screwdriver, remove the scanner unit assembly...

4-102 Service Manual 2. Remove the three screws (A) securing the output cover assembly to the machine. 3. Remove the output cover assembly. Output cover assembly removal (model X658) 1. Open the door assembly, rear. 2. Lift the right side of the fuser exit access panel and remove. A

4-104 Service Manual 4. Release the left and right clips (B). 5. Remove the redrive assembly. Laser cover removal (model X658) B A 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 ...

Repair information 4-105 5. Remove the five screws (A) on the left securing the laser cover. 6. Remove the four screws on the right (B) securing the laser cover. A B 7. Remove the sensor (ADF media exit) fan bracket assembly. See “Sensor (standard bin exit) actuator assembly removal” on page 4-89 .

4-108 Service Manual 2. Remove screw (A) securing standard output bin LED assembly to the scanner support platform. 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 M...

Repair information 4-109 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...

Repair information 4-111 Card reader assembly removal (model X658) 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 1. Remove the operator panel assembly. See...

4-120 Service Manual Print cartridge cover assembly removal (model X658) 1. Open the print cartridge cover assembly. 2. Remove the two screws (A) securing the print cartridge cover assembly. 3. Remove the cartridge access door. A

Repair information 4-123 Side cover, left removal (model X658) 2. Open the cartridge access door. 3. Release the two tabs (A) in the front. 4. Remove the side cover, left. 3. Remove the paper tray. 4. Open the MPF door. 5. Open the cartridge access door. A 1. Remove the cover, left rear corner. See ...

Repair information 4-125 4. Remove the door assembly, rear. Cover, rear lower removal 2. Remove the two screws (A) on each side of the cover. 3. Open the cover, rear lower. 1. Remove the door assembly, rear. See “Door assembly, rear removal” on page 4-124 .

4-128 Service Manual Scanner support inner cover, right removal (model X658) 2. Remove the four screws (A) securing the scanner support inner cover, right to the machine. 3. Pull the bottom out, and remove the scanner support inner cover, right. A 1. Remove the scanner support cover, right rear. See...

Repair information 4-129 Scanner support cover, right removal (model X658) 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 inner cov...

Repair information 4-133 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...

Repair information 4-139 Scanner platen glass cover assembly removal (model X658) 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 ...

4-142 Service Manual 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 suppor...

Repair information 4-143 Carriage belt tensioner assembly removal 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. Remov...

4-144 Service Manual Carriage drive motor assembly with cable removal 2. Loosen the screw (A) on the carriage belt tensioner. 3. Pull slack in the carriage belt and retighten screw (A). 4. Remove the clip (B) on the carriage output shaft. 5. Remove the retaining washer (C) and belt from the motor ou...

Repair information 4-145 8. Remove the four screws (F) securing the carriage drive motor assembly with cable to the flatbed frame. 9. Remove the carriage drive motor assembly with cable. Carriage belt removal 2. Loosen the screw (A) on the carriage belt tensioner. 3. Pull slack in the carriage belt,...

Repair information 4-147 Scanner / ADF duplex CCD exposure lamp removal 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 C...

4-148 Service Manual 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 2. Remove the wire harnesses from the sca...

Repair information 4-149 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 2. Disconnect the cooling fan wiring harness from the scanner interface card connector (CN5) assembly. 3. Remove the two scr...

Repair information 4-153 Sensor (platen glass length) assembly removal 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 lengt...

4-154 Service Manual Sensor (scanner HP) assembly w/bracket removal 2. Remove screw (A) securing the HP sensor bracket to the flatbed frame. 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 2. Remove the...

4-156 Service Manual Option removals High capacity input tray

Repair information 4-157 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. 3. Slide the HC...

4-162 Service Manual High capacity input tray (HCIT) cover, right removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 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 Not...

Repair information 4-165 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...

Repair information 4-167 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. 2. Remove the three...

Repair information 4-169 High capacity input tray (HCIT) controller card assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 2. Disconnect all connectors from the HCIT controller card assembly. 1. Remove the HCIT cover, left. See “High capacity inp...

4-170 Service Manual 3. Remove the three screws (A) securing the HCIT controller card assembly. 4. Remove the HCIT controller card assembly and the shield. High capacity input tray (HCIT) media size actuator assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before ...

4-172 Service Manual 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. 2. Disconnect the sensor (HCIT tray rais...

Repair information 4-173 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. A 1. Remove the HCIT cover, left. See “High capacity input tray (HCIT) cover, left removal” on pag...

Repair information 4-175 High capacity input tray (HCIT) pick arm bracket assembly removal Note: Carefully remove the base machine from the HCIT tray assembly before proceeding. 2. Remove the HCIT pick arm bracket assembly cable connectors from the HCIT controller card assembly. Note: Remove the cab...

Repair information 4-177 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. 2....

4-178 Service Manual 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.

Repair information 4-179 250-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 pi...

4-180 Service Manual 250-sheet media out actuator removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 2. Release the hook (A) securing the 250-sheet media out actuator to the 250-sheet pick arm bracket assembly. 3. Remove the 250-sheet media out act...

Repair information 4-181 Note: The 250-sheet frame assembly is not a FRU. 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-s...

4-184 Service Manual 250-sheet controller card assembly removal 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. 1. Remove the 250-sheet pick ...

4-186 Service Manual Media size actuator removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 2. Remove the screw (A) securing the media size actuator to the 250-sheet frame. 3. Remove the media size actuator. A 1. Remove the 250-sheet controller car...

Repair information 4-187 Media tray catch spring removal Note: Carefully remove the base machine from the input option tray assembly before proceeding. 2. Release the hooks securing the sensor (pass through) to the drawer. 3. Remove the sensor (pass through) from the drawer. 4. Remove the four screw...

4-188 Service Manual 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 sp...

4-190 Service Manual 550-sheet option tray assembly

Repair information 4-191 550-sheet media tray assembly removal Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly. 550-sheet option drawer assembly removal Remove the 550-sheet media tray assembly from the 550-sheet option drawer assembly.

4-192 Service Manual 550-sheet pick arm bracket assembly removal 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...

Repair information 4-193 550-sheet bellcrank recoil spring removal 2. Remove the 550-sheet bellcrank recoil spring from the 550-sheet pick arm bracket assembly. 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) fr...

4-194 Service Manual 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. 2. Turn the drawer over so that you are looking at the bottom...

Repair information 4-195 550-sheet frame assembly removal Note: The 550-sheet frame assembly is not a FRU. 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 t...

Repair information 4-197 Upper interface cable assembly removal 2. Disconnect the upper interface cable connector (A) from the 550-sheet controller card. 3. Release the two hooks (B) securing the options auto connect to the 550-sheet frame. 4. Remove the upper interface cable assembly. Lower interfa...

4-198 Service Manual Sensor (pass through) with cable removal 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 2. Disconnect the three connectors from the 550-sheet c...

4-200 Service Manual Media size actuator removal 2. Remove the screw (A) securing the media size actuator to the 550-sheet frame. 3. Remove the media size actuator. A 1. Remove the 550-sheet controller card assembly. See “550-sheet controller card assembly removal” on page 4-198 .

Repair information 4-201 550-sheet option drive shaft with spring removal 2. Pinch the two hooks (A) on the cap, and detach it from the 550-sheet frame. 3. Pull the drive roll gear (B), the shaft with spring (C), and the bevel out through the opening. 4. Remove the 550-sheet option drive shaft with ...

4-202 Service Manual Media tray catch spring removal 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 2. Remove the tray roller catch assembly from the drawer. 1. Remove the 550-sheet frame as...

Repair information 4-203 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 assem...

4-204 Service Manual MFP stapler assembly left cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. 2. Pull out on the front side of the left cover to disengage the tabs. 3. Remove the left cover. MFP stapler assembly top cover removal A 1. Re...

Repair information 4-205 2. Remove the screw (A) on each side of the top cover. 3. Pull up and toward the front to remove the top cover. MFP stapler assembly handle cover removal A 1. Remove the left and right cover. See “MFP stapler assembly left cover removal” on page 4-204 and “MFP stapler assemb...

4-206 Service Manual 2. Remove the two screws (A) on each side of the. 3. Lift up and to the rear to remove the cover. MFP stapler assembly LED sensor cover removal 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. A A A

Repair information 4-207 4. Remove the LED sensor cover. 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 presen...

4-208 Service Manual MFP stapler assembly sensor (finisher media bin present) removal 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. 3. Remove the harness connected to the media bin present sensor. 4. Remove the sensor (finisher bin media p...

Repair information 4-209 2. Remove the two screws (A) securing the LED to the cover. 3. Remove the LED and disconnect the harness. 4. Remove the LED clear lens. MFP stapler assembly tamper drive belt removal 2. Pull the belt out the tamper belt holder and remove the belt from the pulley. A 1. Remove...

4-210 Service Manual MFP stapler assembly tamper drive motor assembly removal 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 m...

4-212 Service Manual MFP stapler assembly stapler unit assembly removal 2. Remove the four cable harnesses attached to the stapler unit assembly. 3. Remove the three screws (A) securing the stapler unit assembly. 4. Remove the stapler unit assembly. A 1. Remove the right cover. See “MFP stapler asse...

Repair information 4-213 Stapler/stacker controller card assembly removal 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. 4. Remove the stapler/stacker controller card assembly. MFP stapler assembly paddle driv...

Repair information 4-215 MFP stapler assembly sensor (media stack) removal 2. Disconnect the harness to the sensor (media stack). 3. Using your fingers, pinch tab (A) securing the sensor (media stack) and remove. MFP stapler assembly sensor (paddle HP) removal 2. Disconnect the harness to the sensor...

Repair information 4-217 MFP stapler assembly sensor (tamper HP left and right) removal 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. MFP stapler assembly sensor...

4-218 Service Manual 2. Remove the two screws (A) securing the staple finisher sensor (bin full send). 3. Disconnect the harness and remove. MFP stapler assembly sensor (bin full receive) removal 2. Remove the two screws (A) securing the sensor (bin full receive). 3. Disconnect the harness and remov...

Repair information 4-219 MFP stapler assembly sensor (media in stapler) removal 2. Using a flat-blade screwdriver, release the tabs (A) securing the sensor. 3. Using needlenose pliers, carefully grip the sensor and pull it out and disconnect the harness. Replacement Notes: Using needlenose pliers, p...

4-220 Service Manual MFP stapler assembly sensor (deflector HP) removal 2. Disconnect the harness to the sensor (deflector HP). 3. Release the tabs (A) securing the sensor to the unit. Note: The tabs may be difficult to access. The use of a spring hook or flat-blade screwdriver may be necessary to r...

Repair information 4-221 4-bin mailbox assembly left cover removal 1. Place the 4-bin mailbox assembly on its side. 2. Remove the two screws (A) on the underside of the 4-bin mailbox assembly securing the left cover. 3. Using your finger, pull up on the top surface of the left cover while simultaneo...

Repair information 4-223 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 3. Remove the 4-bin mailbox assembly left rear inner cover. 4. Release the tabs securing the sensor (deflector gate HP) and remove t...

4-224 Service Manual 4-bin mailbox assembly rear door assembly removal 1. Open the rear door. 2. Gently spread each side of the 4-bin mailbox assembly until the rear door hinge is free to be removed. 3. Remove the rear door assembly.

Repair information 4-225 4-bin mailbox assembly right cover removal 1. Place the 4-bin mailbox assembly on its side. 2. Remove the two screws (A) from the bottom side of the right cover securing cover in place. 3. Using your fingers, pull up on the top of the right cover and pull out simultaneously ...

4-226 Service Manual 3. Remove the three screws (A) securing the LED card assembly to the 4-bin mailbox assembly. 4. Remove the 4-bin mailbox assembly LED card assembly. 4-bin mailbox assembly top cover removal 3. Remove the four screws (A) on each side of the top cover securing it to the 4-bin mail...

Repair information 4-227 4. Slide the top cover towards the rear and remove. 4-bin mailbox assembly deflector gate solenoid removal 2. Remove the screw (A) securing the deflector gate solenoid to the 4-bin mailbox assembly. 3. Carefully unroute the deflector gate solenoid cables from the cable clips...

4-228 Service Manual 4-bin mailbox assembly transport solenoid removal 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. 5. Remove the transport solenoid and...

Repair information 4-229 4-bin mailbox assembly spring removal 2. Using a spring hook or needlenose pliers, remove the spring off the hooks. 1. Remove the 4-bin mailbox assembly rear door assembly. See “4-bin mailbox assembly rear door assembly removal” on page 4-224 .

4-230 Service Manual 4-bin mailbox assembly deflector gate (bin 1 through 3) removal 2. Remove the 4-bin mailbox assembly right rear inner cover. 4. Grasp the deflector gate and pull it out of its socket on each side. Carefully remove the diverter from the machine. 1. Remove the 4-bin mailbox assemb...

4-232 Service Manual 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 screwdrive...

4-234 Service Manual 4-bin mailbox assembly standard output bin LED removal 1. Remove the three screws (A) on the underside of bin 1 securing the output bin LED bracket. 2. Pull the output bin LED bracket out from the underside of bin 1 and disconnect the LED harness. A

4-236 Service Manual 4-bin mailbox assembly LED clear lens removal 2. Remove the output bin LED clear lens from the output bin LED bracket. 4-bin mailbox assembly media bin full actuator removal 2. Pry the front hinge of the media bin full actuator towards the rear until the front boss is released f...

Repair information 4-237 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 disenga...

4-238 Service Manual Offset stacker left cover removal 1. Remove the two screws (A) on the inside of the exit bin compartment securing the left cover. 2. Pull out on the front side of the left cover to disengage the tabs. 3. Remove the offset stacker left cover. Offset stacker top cover removal A 1....

Repair information 4-239 2. Remove the screw (A) on each side of the top cover. 3. Pull up and toward the front to remove the offset stacker top cover. Offset stacker handle cover removal A 1. Remove the left and right cover. See “Offset stacker left cover removal” on page 4-238 and “Offset stacker ...

4-240 Service Manual 2. Remove the two screws (A) on each side of the offset stacker. 3. Lift up and to the rear to remove the cover. Offset stacker LED sensor cover removal 1. Remove the screw (A) securing the LED sensor cover to the underside of the output bin. A A A

Repair information 4-241 4. Remove the LED sensor cover. 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 pre...

4-242 Service Manual Offset stacker sensor (finisher media bin present) removal 2. Using a flat-blade screwdriver, release the tabs (A) on the sensor and remove it from the sensor cover. 3. Remove the harness connected to the media bin present sensor. 4. Remove the offset stacker sensor (finisher bi...

Repair information 4-243 2. Remove the two screws (A) securing the LED to the cover. 3. Remove the LED and disconnect the harness. 4. Remove the LED clear lens. Offset stacker tamper drive belt removal 2. Pull the belt out the tamper belt holder and remove the belt from the pulley. A 1. Remove the o...

4-244 Service Manual Offset stacker tamper drive motor assembly removal 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 a...

4-246 Service Manual Stapler/stacker controller card assembly removal 2. Disconnect all harnesses to the controller card. 3. Remove the three screws (A) securing the stapler/stacker controller card assembly. 4. Remove the stapler/stacker controller card assembly. Offset stacker paddle drive motor as...

Repair information 4-247 4. Remove the two screws (A) securing the two paddle drive motor assemblies. 5. Remove the paddle drive motor assembly. Offset stacker sensor (media stack) removal 2. Disconnect the harness to the sensor (media stack). A 1. Remove the offset stacker top cover. See “Offset st...

4-248 Service Manual 3. Using your fingers, pinch tab (A) securing the offset stacker sensor (media stack) and remove. Offset stacker sensor (paddle HP) removal 2. Disconnect the harness to the offset stacker sensor (paddle home position). 3. Using your fingers, pinch tab (A) securing the offset sta...

Repair information 4-249 Offset stacker sensor (tamper HP left and right) removal 2. Disconnect the harness to the offset stacker sensor (tamper HP left and right). 3. Using your fingers, pinch the tabs securing the staple finisher sensor (tamper HP left and right) and remove. Offset stacker sensor ...

4-250 Service Manual 2. Remove the two screws (A) securing the staple finisher sensor (bin full send). 3. Disconnect the harness and remove. Offset stacker sensor (bin full receive) removal 2. Remove the two screws (A) securing the sensor (bin full receive). 3. Disconnect the harness and remove. A A...

Repair information 4-251 Offset stacker sensor (deflector HP) removal 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 ...

Connector locations 5-1 5. Connector locations Locations Sensors–Flatbed Switch (ADFclosed interlock) Sensor (Media exit) Sensor (ADF lowerdoor interlock) Sensor (ADF document set) Sensor (ADF front registration) Sensor (ADF sheet through) Sensor (ADF top door interlock) Sensor (ADF media length) AD...

Preventive maintenance 6-1 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...

6-2 Service Manual Scheduled maintenance Maintenance kit The operator panel displays the message 80 Scheduled Maintenance at each 300K page count interval. It is necessary to replace the fuser assembly, transfer roller, charge roll, and pick tires at this interval to maintain the print quality and r...

Preventive maintenance 6-3 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 w...

Parts catalog 7-1 • Part number : Identifies the unique number that identifies this FRU. • Units/mach : Refers to the number of units actually used in the base machine or product. • Units/option : Refers to the number of units in a particular option. It does not include the rest of the base machine....

7-8 Service Manual Assembly 4: Media path and ducts

Parts catalog 7-9 Assembly 4: Media path and ducts Asm- Index Partnumber 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...

7-10 Service Manual Assembly 5: Pick arm and media tray assemblies

Parts catalog 7-11 Assembly 5: Pick arm and media tray assemblies Asm- Index Partnumber 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 40X1...

7-18 Service Manual Assembly 9: Fuser and LVPS card assemblies

Parts catalog 7-19 Assembly 9: Fuser and LVPS card assemblies Asm- index Partnumber 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...

Parts catalog 7-21 Assembly 10: Flatbed scanner Asm- index Partnumber 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 senso...

7-22 Service Manual Assembly 11: ADF unit assembly 1

Parts catalog 7-23 Assembly 11: ADF unit assembly Asm- index Partnumber 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 7-25 Assembly 12: ADF covers Asm- index Partnumber 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 ...

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

Parts catalog 7-27 Assembly 13: ADF feed and drive Asm- index Partnumber 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 T...

Parts catalog 7-29 Assembly 14: ADF electronics Asm- index Partnumber 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 ...

7-38 Service Manual Assembly 19: MFP stapler assembly 1

7-46 Service Manual Assembly 23: MFP offset stacker assembly #1 1

Parts catalog 7-47 Assembly 23: MFP offset stacker assembly #1 Asm- Index Partnumber Units/mach Units/ kit or pkg Description 1 40X7025 1 1 MFP offset stacker assembly (comes completely assembled)

7-60 Service Manual Assembly 30: Miscellaneous Asm- Index Partnumber Units/mach Units/ kit or pkg Description NS 7372935 1 1 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 (...

7-62 Service Manual Assembly 31: Power cords Asm- Index Partnumber 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, Austr...

Parts catalog 7-63 Assembly 32: Universal trays and accessories Asm- Index Partnumber 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 40X585...

Index I-1 Index A 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...

Part number index I-5 Part number index P/N Description Page 40X0269 Power cord LV, USA & Canada, Latin America 40X0271 Power cord HV, Asian, Brunei, Cambodia, Indonesia, Laos, Malaysia, Myanmar, Philippines, Singapore, 40X0273 Power cord HV, Chile, Uruguay 40X0301 Power cord HV, Australia &...

Print defects guide Page 1 of 1 Print defects guide 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 fuser Replace the transfer roller Match a set of repeating defects on a print job to the marks on one o...

J26 J22 J15 2 1 3 4 J16 2 1 3 4 6 5 7 J20 12 13 2 1 3 4 6 8 10 5 7 9 11 J24 2 1 3 4 6 8 5 7 9 J35 231 J34 21 2 1 3 4 2 1 3 4 J9 213 J8 213 J7 81 234567 9 101112 J6 L VPS Card Assembly CN3 2 1 3 4 2 7 6 5 4 3 1 Printhead Assembly GND +24V S MAIN F AN FEEDBA CK Sensor (STD Bin Full) 2 1 3 4 6 8 10 5 7...