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T650

Lexmark T650, T652, T654 Series, T656 Series User manual

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T650, T652, T654, and T656
4062-xxxx
Service Manual
• Start diagnostics
• Maintenance
• Safety and notices
• Trademarks
• Index
July 12, 2016 www.lexmark.com
P/N 12G9824
Product information
Product name:
Lexmark T650, T652, T654, and T656
Machine type:
4062
Model(s):
01A, 21A, 23A, 41A, 43A, 630
Edition notice
July 12, 2016
The following paragraph does not apply to any country where such provisions are inconsistent with local law: LEXMARK
INTERNATIONAL, INC., PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR
IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement
may not apply to you.
This publication could include technical inaccuracies or typographical errors. Changes are periodically made to the information
herein; these changes will be incorporated in later editions. Improvements or changes in the products or the programs described
may be made at any time.
References in this publication to products, programs, or services do not imply that the manufacturer intends to make these available
in all countries in which it operates. Any reference to a product, program, or service is not intended to state or imply that only that
product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any
existing intellectual property right may be used instead. Evaluation and verification of operation in conjunction with other products,
programs, or services, except those expressly designated by the manufacturer, are the user’s responsibility.
Trademarks
Lexmark and the Lexmark logo are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.
PCL® is a registered trademark of the Hewlett-Packard Company. PCL is Hewlett-Packard Company’s designation of a set of printer
commands (language) and functions included in its printer products. This printer is intended to be compatible with the PCL language.
This means the printer recognizes PCL commands used in various application programs, and that the printer emulates the functions
corresponding to the commands.
PostScript is a registered trademark of Adobe Systems Incorporated in the United States and/or other countries.
All other trademarks are the property of their respective owners.
© 2016 Lexmark International, Inc.
All rights reserved.
P/N 12G9824
4062
Table of contents
Product information......................................................................................2
Edition notice.................................................................................................2
Notices and safety information................................................................. 17
Laser notices........................................................................................................................................................17
Safety information.............................................................................................................................................20
Preface......................................................................................................... 25
Service manual conventions.......................................................................................................................... 25
Change history...................................................................................................................................................25
General information................................................................................... 29
Media guidelines............................................................................................................................................... 29
Supported paper sizes, types, and weights......................................................................................................... 29
Tools required for service................................................................................................................................33
Diagnostic information.............................................................................. 35
Troubleshooting overview.............................................................................................................................. 35
Performing the initial troubleshooting check....................................................................................................... 35
Power‑on Reset (POR) sequence............................................................................................................................ 36
Using Safe Mode ......................................................................................................................................................... 36
Fixing print quality issues................................................................................................................................ 37
Initial print quality check............................................................................................................................................ 38
Faint print (low contrast) check................................................................................................................................ 38
Repeating defects check........................................................................................................................................... 40
Blank pages check...................................................................................................................................................... 40
Solid black pages check............................................................................................................................................ 42
Vertical lines and bands (process direction) check............................................................................................ 44
Horizontal white stripes and bands (side to side direction) check ................................................................ 45
Vertical stripes (process direction) check ............................................................................................................. 46
Horizontal stripes (side to side direction) check..................................................................................................47
Partial lack check......................................................................................................................................................... 48
Spots check .................................................................................................................................................................. 49
Background (fog) check.............................................................................................................................................. 51
Skew check................................................................................................................................................................... 52
Media damage check................................................................................................................................................. 53
No fuse check .............................................................................................................................................................. 54
Paper jams...........................................................................................................................................................55
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Avoiding jams...............................................................................................................................................................55
Understanding jam numbers and locations ......................................................................................................... 56
How to clear 200-201 paper jams .......................................................................................................................... 57
How to clear 202-203 paper jams..........................................................................................................................80
How to clear 230 paper jams................................................................................................................................... 93
How to clear 231-239 paper jams..........................................................................................................................104
How to clear 241-245 paper jams...........................................................................................................................115
How to clear 250 paper jams...................................................................................................................................131
How to clear 260 paper jams..................................................................................................................................132
How to clear 270 paper jams.................................................................................................................................. 137
How to clear 280 paper jams..................................................................................................................................144
Understanding the printer messages.........................................................................................................158
Activating Menu Changes........................................................................................................................................158
Busy ...............................................................................................................................................................................158
Cancel not available ..................................................................................................................................................158
Canceling......................................................................................................................................................................158
Change <src> to <x> ..................................................................................................................................................158
Check duplex connection ........................................................................................................................................159
Check tray <x> connection ......................................................................................................................................159
Clearing job accounting statistics ..........................................................................................................................159
Close door or insert cartridge.................................................................................................................................159
Close finisher side door............................................................................................................................................159
Defragmenting Flash DO NOT POWER OFF.......................................................................................................160
Deleting.........................................................................................................................................................................160
Deleting held jobs ......................................................................................................................................................160
Deletion complete......................................................................................................................................................160
Deletion failed .............................................................................................................................................................160
Disabling DLEs ............................................................................................................................................................160
Disabling Menus .........................................................................................................................................................160
Disk Corrupted............................................................................................................................................................160
Disk recovery x/y XX% DO NOT POWER OFF....................................................................................................160
Enabling Menus ...........................................................................................................................................................161
Encrypting disk x/y XX% DO NOT POWER OFF..................................................................................................161
Enter PIN........................................................................................................................................................................161
Error reading USB drive.............................................................................................................................................161
Flushing buer .............................................................................................................................................................161
Formatting Disk x/y XX% DO NOT POWER OFF.................................................................................................161
Formatting Flash DO NOT POWER OFF................................................................................................................161
Hex Trace Ready..........................................................................................................................................................161
Insert staple cartridge ...............................................................................................................................................162
Insert Tray <x> .............................................................................................................................................................162
Install bin <x> ...............................................................................................................................................................162
Install duplex................................................................................................................................................................162
Install envelope feeder .............................................................................................................................................162
Install Tray <x> .............................................................................................................................................................163
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Install MICR Cartridge................................................................................................................................................163
Invalid Engine Code...................................................................................................................................................163
Invalid Network Code................................................................................................................................................163
Invalid PIN.....................................................................................................................................................................163
Load manual feeder with <x> ..................................................................................................................................163
Load <src> with <x>....................................................................................................................................................164
Load staples.................................................................................................................................................................164
Maintenance ................................................................................................................................................................164
Menu access turned o by system administrator..............................................................................................164
Menus are Disabled...................................................................................................................................................164
Must be in Ready state to enter menus................................................................................................................164
Network/Network <x>/Network <x>, <y>..............................................................................................................164
No held jobs.................................................................................................................................................................165
No jobs found..............................................................................................................................................................165
No jobs to cancel........................................................................................................................................................165
Not Ready.....................................................................................................................................................................165
No recognized file types ..........................................................................................................................................165
Overflow bin full..........................................................................................................................................................165
Parallel/Parallel <x> ....................................................................................................................................................165
[PJL RDYMSG]..............................................................................................................................................................165
Power Saver.................................................................................................................................................................166
Printer busy, Continue, Quit.....................................................................................................................................166
Printing ..........................................................................................................................................................................166
Printing from USB drive DO NOT REMOVE.........................................................................................................166
Programming disk DO NOT POWER OFF............................................................................................................166
Programming flash DO NOT POWER OFF...........................................................................................................166
Reading USB drive DO NOT REMOVE .................................................................................................................166
Ready.............................................................................................................................................................................166
Reattach bin <x>..........................................................................................................................................................167
Reattach bin <x> – <y> ..............................................................................................................................................167
Reattach envelope feeder........................................................................................................................................167
Remote Management Active DO NOT POWER OFF ........................................................................................168
Remove packaging material, check <x>...............................................................................................................168
Remove paper from all bins.....................................................................................................................................168
Remove paper from bin <x>.....................................................................................................................................168
Remove paper from standard output bin.............................................................................................................168
Remove paper from <linked bin set name>.........................................................................................................168
Replace wiper..............................................................................................................................................................168
Resetting active bin ...................................................................................................................................................169
Resetting the printer..................................................................................................................................................169
Resetting without replacing may aect print quality. ........................................................................................169
Restoring Factory Defaults.......................................................................................................................................169
Restore Held Jobs?....................................................................................................................................................169
Restoring Held Job(s) x/y..........................................................................................................................................169
Routine maintenance needed.................................................................................................................................169
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Securely clearing disk space...................................................................................................................................170
Serial <x> ......................................................................................................................................................................170
Some held jobs were lost.........................................................................................................................................170
Staples <x> empty or misfed ...................................................................................................................................170
Staples <x> low or missing.......................................................................................................................................170
Standard Bin Full ........................................................................................................................................................170
Submitting selection..................................................................................................................................................170
Too many failed panel logins...................................................................................................................................170
Toner low .......................................................................................................................................................................171
Tray <x> Empty .............................................................................................................................................................171
Tray <x> Low .................................................................................................................................................................171
Tray <x> Missing........................................................................................................................................................... 171
Unsupported disk........................................................................................................................................................171
Unsupported USB device, please remove ...........................................................................................................171
Unsupported USB hub, please remove.................................................................................................................171
USB/USB <x> ................................................................................................................................................................171
USB drive removed..................................................................................................................................................... 171
View supplies ............................................................................................................................................................... 171
Waiting...........................................................................................................................................................................172
30 Invalid refill, change cartridge...........................................................................................................................172
31 Replace defective cartridge................................................................................................................................172
32 Cartridge part number unsupported by device ...........................................................................................172
34 Short paper ............................................................................................................................................................172
35 Insucient memory to support Resource Save feature.............................................................................172
37 Insucient memory for Flash Memory Defragment operation................................................................. 173
37 Insucient memory to collate job .................................................................................................................... 173
37 Insucient memory, some held jobs were deleted .................................................................................... 173
37 Insucient memory, some Held Jobs will not be restored .......................................................................173
38 Memory full ............................................................................................................................................................ 173
39 Complex page, some data may not have printed ....................................................................................... 173
42.xy Cartridge region mismatch........................................................................................................................... 174
50 PPDS font error..................................................................................................................................................... 174
51 Defective flash detected .....................................................................................................................................174
52 Not enough free space in flash memory for resources ............................................................................. 174
53 Unformatted flash detected...............................................................................................................................175
54 Serial option <x> error.........................................................................................................................................175
54 Network <x> software error...............................................................................................................................175
54 Standard network software error.....................................................................................................................175
55 Unsupported option in slot <x> ........................................................................................................................175
56 Parallel port <x> disabled...................................................................................................................................176
56 Serial port <x> disabled ......................................................................................................................................176
56 Standard parallel port disabled ........................................................................................................................176
56 Standard USB port disabled..............................................................................................................................176
57 Configuration change, some held jobs were not restored .......................................................................176
58 Too many bins attached ..................................................................................................................................... 177
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58 Too many disks installed .................................................................................................................................... 177
58 Too many flash options installed...................................................................................................................... 177
58 Too many trays attached .................................................................................................................................... 177
59 Incompatible Duplex ...........................................................................................................................................178
59 Incompatible envelope feeder .........................................................................................................................178
59 Incompatible output bin <x>..............................................................................................................................178
59 Incompatible tray <x> ..........................................................................................................................................178
61 Remove defective hard disk...............................................................................................................................178
62 Disk full....................................................................................................................................................................179
80 Routine maintenance needed ..........................................................................................................................179
81 Routine Maintenance ...........................................................................................................................................179
88 Cartridge low.........................................................................................................................................................179
88.yy Cartridge nearly low .......................................................................................................................................179
88.yy Replace cartridge ............................................................................................................................................179
200–282 Paper jam ..................................................................................................................................................179
1565 Emulation error, load emulation option ......................................................................................................180
User attendance messages.......................................................................................................................... 180
User attendance messages (0‑99) ........................................................................................................................180
System timeout service check................................................................................................................................183
Invalid print cartridge service check .....................................................................................................................183
Defective print cartridge service check................................................................................................................183
Short paper service check .......................................................................................................................................184
Resource Save o deficient memory service check.........................................................................................184
Insucient Collation Area service check.............................................................................................................185
Insucient Memory service check ........................................................................................................................185
Memory Full service check ......................................................................................................................................185
RFID error service check..........................................................................................................................................186
RFID error service check..........................................................................................................................................186
RFID error service check..........................................................................................................................................187
Cartridge Region Mismatch service check..........................................................................................................187
PPDS Font Error service check...............................................................................................................................187
Defective or full Flash service check ....................................................................................................................187
Network service check .............................................................................................................................................188
Network software eror service check...................................................................................................................190
Unsupported Option in Slot [x] service check ....................................................................................................190
Invalid Tray Configuration service check ..............................................................................................................191
Too Many Bins Attached service check ................................................................................................................191
Too Many Disks Attached service check ..............................................................................................................191
Too Many Flash Options service check.................................................................................................................191
Too Many Trays Attached service check..............................................................................................................192
Incompatible Duplex service check ......................................................................................................................192
Incompatible Envelope Feeder service check ...................................................................................................192
Incompatible Output Bin [x] service check..........................................................................................................192
Incompatible Output Tray [x] service check ........................................................................................................193
Defective Disk service check..................................................................................................................................193
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Disk Full service check .............................................................................................................................................193
Routine Maintenance Needed service check.....................................................................................................193
Replace fuser service check....................................................................................................................................194
Replace cartridge service check............................................................................................................................194
Printer hardware errors.................................................................................................................................. 194
Procedure before starting the 9yy service checks ...........................................................................................194
9yy errors......................................................................................................................................................................196
Service menus...........................................................................................233
Understanding the printer control panel.................................................................................................. 233
Understanding the colors of the Sleep button and indicator lights.................................................. 235
Diagnostics menu........................................................................................................................................... 235
Entering the Diagnostics menu .............................................................................................................................235
Exiting the Diagnostics menu.................................................................................................................................236
Registration .................................................................................................................................................................236
PRINT TESTS ..............................................................................................................................................................237
HARDWARE TESTS...................................................................................................................................................239
DUPLEX TESTS...........................................................................................................................................................241
INPUT TRAY TESTS ..................................................................................................................................................244
OUTPUT BIN TESTS .................................................................................................................................................245
StapleSmart FINISHER TESTS................................................................................................................................248
BASE SENSOR TEST ................................................................................................................................................249
DEVICE TESTS ...........................................................................................................................................................249
PRINTER SETUP........................................................................................................................................................ 250
EP SETUP ....................................................................................................................................................................252
REPORTS .....................................................................................................................................................................254
EVENT LOG.................................................................................................................................................................254
Configuration menu....................................................................................................................................... 255
Maintenance page count ........................................................................................................................................255
Maintenance page counter reset..........................................................................................................................255
Print quality pages.....................................................................................................................................................255
Reports .........................................................................................................................................................................255
SIZE SENSING ............................................................................................................................................................256
Panel Menus ...............................................................................................................................................................256
PPDS Emulation .........................................................................................................................................................257
Demo Mode ................................................................................................................................................................257
Factory Defaults.........................................................................................................................................................257
LES Applications........................................................................................................................................................257
Energy Conserve.......................................................................................................................................................258
Paper Prompts............................................................................................................................................................258
Envelope Prompts.....................................................................................................................................................258
Action for Prompts ....................................................................................................................................................259
Jobs on Disk ...............................................................................................................................................................259
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Disk Encryption..........................................................................................................................................................259
Wipe Disk.....................................................................................................................................................................259
Font Sharpening ....................................................................................................................................................... 260
Wiper Messages ....................................................................................................................................................... 260
Key Repeat Initial Delay .......................................................................................................................................... 260
Key Repeat Rate .........................................................................................................................................................261
Clear Custom Status..................................................................................................................................................261
USB Speed...................................................................................................................................................................261
Best Speed...................................................................................................................................................................261
Repair information....................................................................................263
Removal precautions..................................................................................................................................... 263
Handling ESD‑sensitive parts.................................................................................................................................263
Adjustments..................................................................................................................................................... 264
Printer skew specifications .....................................................................................................................................264
Polygon and Oscillating printhead mechanical registration adjustment....................................................266
Oscillating printhead assembly electronic adjustment ...................................................................................267
Alignment assembly adjustment ...........................................................................................................................268
Fuser solenoid adjustment .....................................................................................................................................269
Gap adjustment..........................................................................................................................................................269
Removal procedures......................................................................................................................................270
Left side removals...........................................................................................................................................270
Access door removal................................................................................................................................................270
Alignment assembly removal..................................................................................................................................271
Main cooling fan removal ........................................................................................................................................273
Main drive motor assembly removal ....................................................................................................................274
MPF pick solenoid assembly removal .................................................................................................................275
Print cartridge clamp assembly removal.............................................................................................................278
Print cartridge ID connector assembly removal................................................................................................279
T650 left side cover removal .................................................................................................................................279
T652, T654, and T656 left side cover removal ............................................................................................... 280
Switch (media size) assembly removal ...............................................................................................................282
System card assembly removal.............................................................................................................................283
NVM card assembly removal .................................................................................................................................285
Right side removals........................................................................................................................................ 287
T652, T654, and T656 duplex cooling fan removal ........................................................................................287
Fuser drive release linkage removal....................................................................................................................287
HVPS card assembly removal................................................................................................................................288
Laser cover removal .................................................................................................................................................289
T650 LVPS card assembly removal..................................................................................................................... 290
T652, T654, and T656 LVPS card assembly removal.....................................................................................292
Print cartridge cooling fan removal ......................................................................................................................293
T650 right side cover removal...............................................................................................................................294
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T652, T654, and T656 right side cover removal..............................................................................................295
Sensor (toner empty) removal................................................................................................................................296
Sensor (input) removal ............................................................................................................................................296
Front side removals........................................................................................................................................297
Charge roll assembly removal ...............................................................................................................................297
T650, T652, and T654 LCD screen bezel removal..........................................................................................298
Inner deflector removal............................................................................................................................................299
Media turn guide removal ...................................................................................................................................... 300
MPF lift plate assembly removal........................................................................................................................... 300
MPF media out actuator removal...........................................................................................................................301
MPF pick roll assembly removal.............................................................................................................................301
T650, T652, and T654 MPF tray door assembly removal..............................................................................302
T650, T652, and T654 operator panel latch assembly removal..................................................................304
T650, T652, and T654 operator panel door assembly removal ..................................................................305
T650, T652, and T654 left operator panel hinge assembly removal .........................................................306
T650, T652, and T654 right operator panel hinge assembly removal.......................................................308
T656 operator panel door assembly removal....................................................................................................310
T656 Operator panel cover latch assembly removal .......................................................................................313
Sensor shield assembly removal ..........................................................................................................................313
Transfer roll assembly removal...............................................................................................................................314
Left transfer roll bracket assembly removal ........................................................................................................314
Right transfer roll bracket assembly removal .....................................................................................................315
Transfer deflector removal.......................................................................................................................................316
Bottom side removals.....................................................................................................................................316
T652, T654, and T656 duplex assembly removal ............................................................................................316
T652, T654, and T656 duplex input sensor assembly removal.................................................................... 317
T652, T654, and T656 front duplex guide assembly removal ...................................................................... 317
Media out actuator removal.....................................................................................................................................319
Option drive shaft removal ......................................................................................................................................319
Pick arm assembly removal ....................................................................................................................................320
Pick roll assembly removal .....................................................................................................................................322
Sensor (media level) removal ................................................................................................................................323
Sensor (media out) removal ...................................................................................................................................323
Rear side removals......................................................................................................................................... 324
Rear connection access cover removal ..............................................................................................................324
T650 rear connection bezel assembly removal ...............................................................................................324
T652 and T654 rear connection bezel assembly removal ............................................................................325
T650 rear lower cover assembly removal..........................................................................................................326
T652 and T654 rear lower cover assembly removal ......................................................................................326
Rear door assembly removal..................................................................................................................................327
T652, T654, and T656 rear duplex guide assembly removal.......................................................................327
T652, T654, and T656 duplex drive motor assembly removal ....................................................................328
Fuser access door assembly removal .................................................................................................................330
Fuser unit assembly removal ..................................................................................................................................331
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Redrive assembly removal.......................................................................................................................................331
Top side removals...........................................................................................................................................332
Fuser wiper cover assembly removal ..................................................................................................................332
Media support removal............................................................................................................................................333
Output cover assembly removal ...........................................................................................................................333
T650 printhead assembly removal.......................................................................................................................334
T652, T654, and T656 printhead assembly removal......................................................................................336
MPF cam gear removal..................................................................................................................................337
T652, T654, and T656 redrive motor assembly removal.................................................................... 338
Sensor (duplex input) removal (T652, T654, T656)...............................................................................340
Sensor (standard bin exit) removal .............................................................................................................341
Sensor (toner density) removal ................................................................................................................... 341
Standard bin actuator assembly removal .................................................................................................341
Tray roller catch assembly removal............................................................................................................342
5-bin mailbox removals................................................................................................................................. 343
5-bin mailbox rear door assembly removal........................................................................................................343
5-bin mailbox left outer cover removal................................................................................................................344
5-bin mailbox left inner cover removal ................................................................................................................344
5-bin mailbox right outer cover removal .............................................................................................................345
5-bin mailbox right inner cover removal..............................................................................................................346
5-bin mailbox top cover removal........................................................................................................................... 347
5-bin mailbox media bin full actuator removal ..................................................................................................348
Sensor (5-bin mailbox pass through) removal ...................................................................................................348
Sensor (5-bin mailbox media bin empty) removal ............................................................................................350
5-bin mailbox controller card assembly removal ..............................................................................................350
5-bin mailbox static brush mylar assembly removal .........................................................................................351
5-bin mailbox media bin fifth deflector removal................................................................................................352
5-bin mailbox media bin first through fourth deflector removal ...................................................................353
5-bin mailbox media bin extension assembly removal ...................................................................................354
5-bin mailbox deflector gate solenoid removal.................................................................................................354
5-bin mailbox transport solenoid removal ..........................................................................................................356
Sensor (5-bin mailbox sensor deflector gate HP) removal.............................................................................356
250-sheet option tray removals..................................................................................................................359
250-sheet media tray assembly removal............................................................................................................359
250-sheet tray pick arm bracket assembly removal........................................................................................359
250-sheet tray media out actuator removal.......................................................................................................360
250-sheet tray frame assembly removal .............................................................................................................361
250-sheet tray controller card assembly removal............................................................................................362
550-sheet option tray removals..................................................................................................................364
550-sheet media tray assembly removal............................................................................................................364
550-sheet tray pick arm bracket assembly removal........................................................................................364
550-sheet tray bellcrank recoil spring removal ................................................................................................366
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550-sheet tray frame assembly removal ............................................................................................................366
550-sheet tray controller card assembly removal............................................................................................368
550-sheet tray option drive shaft with spring removal ...................................................................................369
Anti-tip latch assembly removal.............................................................................................................................370
High capacity input tray (HCIT) removals................................................................................................. 372
High capacity input tray (HCIT) media tray assembly removal...................................................................... 372
High capacity input tray (HCIT) tray cover, front removal ............................................................................... 373
High capacity input tray (HCIT) cover, rear removal.........................................................................................375
High capacity input tray (HCIT) cover, right removal........................................................................................376
High capacity input tray (HCIT) cover, left removal .......................................................................................... 378
High capacity input tray (HCIT) anti-tip latch assembly removal ..................................................................380
High capacity input tray (HCIT) drawer slide assembly removal ...................................................................381
High capacity input tray (HCIT) tray lift drive motor assembly removal......................................................382
High capacity input tray (HCIT) controller card assembly removal..............................................................383
High capacity input tray (HCIT) media size actuator assembly removal.....................................................384
High capacity input tray (HCIT) pick arm bracket assembly removal..........................................................387
High capacity input tray (HCIT) tray closed latch with spring removal........................................................389
High capacity stacker removals..................................................................................................................389
High capacity stacker rear door assembly removal.........................................................................................389
High capacity stacker right cover removal.........................................................................................................390
High capacity stacker left cover removal.............................................................................................................391
High capacity stacker media output bin assembly removal ...........................................................................391
High capacity stacker controller card cover panel removal ..........................................................................392
High capacity stacker switch (media bin HP) removal.....................................................................................393
High capacity stacker sensor (media bin full) assembly removal.................................................................393
High capacity stacker sensor (media bin full) bracket assembly removal .................................................394
High capacity stacker controller card assembly (upper and lower) removal ............................................395
High capacity stacker right frame removal.........................................................................................................395
High capacity stacker left frame removal ...........................................................................................................396
High capacity stacker upper deflector gate removal ......................................................................................398
Sensor (high capacity stacker pass through) removal.....................................................................................399
High capacity stacker left mounting bracket removal......................................................................................401
Sensor (high capacity stacker deflector gate HP) removal .............................................................................401
Other removals................................................................................................................................................402
RFID UHF option installation and removal..........................................................................................................402
Lower interface cable assembly removal .............................................................................................................411
Media size actuator removal ...................................................................................................................................412
Media tray catch spring removal ............................................................................................................................412
T652 and T654 media out actuator removal......................................................................................................413
Media size actuator removal ...................................................................................................................................414
Media tray catch spring removal ............................................................................................................................414
Media tray roller catch assembly removal...........................................................................................................415
Sensor (HCIT tray raised HP) with cable assembly removal...........................................................................415
Sensor (HCIT pass through) with cable removal................................................................................................417
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Sensor (pass through) with cable removal ..........................................................................................................418
Sensor (pass through) with cable removal ..........................................................................................................418
Tray roller catch assembly removal .......................................................................................................................419
Tray roller catch assembly removal .......................................................................................................................419
Upper interface cable assembly removal ............................................................................................................419
Output expander removals.......................................................................................................................... 420
Output expander rear door assembly removal .................................................................................................420
Output expander left outer cover removal..........................................................................................................421
Output expander left inner cover removal ..........................................................................................................421
Output expander right outer cover removal ......................................................................................................422
Output expander right inner cover removal.......................................................................................................422
Output expander media bin latch (left and right) removal..............................................................................423
Output expander media output bin assembly removal...................................................................................423
Output expander media bin full actuator removal............................................................................................424
Output expander sensors (media bin full) assembly removal .......................................................................424
Output expander sensor (media bin full) bracket assembly removal..........................................................426
Output expander controller card cover panel removal...................................................................................427
Output expander controller card removal ..........................................................................................................427
Sensor (output expander pass through) removal .............................................................................................428
Output expander deflector gate removal ...........................................................................................................429
Sensor (output expander deflector gate HP) removal.....................................................................................430
SFP stapler assembly removals................................................................................................................... 431
SFP stapler assembly rear door assembly removal..........................................................................................431
SFP stapler assembly right cover removal .........................................................................................................432
SFP stapler assembly left cover removal............................................................................................................433
SFP stapler assembly top cover removal............................................................................................................434
SFP stapler assembly handle cover removal.....................................................................................................435
SFP stapler assembly LED sensor cover removal ............................................................................................436
Sensor (SFP stapler assembly finisher bin media present) removal............................................................ 437
SFP stapler assembly standard output bin LED and LED clear lens removal ...........................................438
SFP stapler assembly tamper drive belt removal .............................................................................................439
SFP stapler assembly tamper drive motor assembly removal ......................................................................439
SFP stapler assembly media stack flap and media stack flap actuator removal......................................440
SFP stapler assembly stapler unit assembly removal ......................................................................................441
SFP stapler assembly paddle drive motor assembly removal ......................................................................442
Sensor (SFP stapler assembly media stack) removal ......................................................................................442
Sensor (SFP stapler assembly paddle HP) removal .........................................................................................443
Sensor (SFP stapler assembly stapler access door interlock) removal ......................................................444
Sensor (SFP stapler assembly tamper HP left and right) removal................................................................444
Sensor (SFP stapler assembly bin full send) removal......................................................................................446
Sensor (SFP stapler assembly bin full receive) removal ................................................................................. 447
Sensor (SFP stapler assembly media in stapler) removal...............................................................................448
Sensor (SFP stapler assembly deflector HP) removal .....................................................................................449
Stapler/stacker controller card assembly removal...........................................................................................450
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Component locations............................................................................... 451
T650, T652, and T654 exterior locations................................................................................................. 451
Printer configurations ................................................................................................................................................451
T656 exterior locations................................................................................................................................. 453
Printer configurations ...............................................................................................................................................453
Connectors....................................................................................................................................................... 454
Controller board.........................................................................................................................................................454
Maintenance............................................................................................. 455
Inspection guide..............................................................................................................................................455
Individual maintenance part expected life...............................................................................................455
Scheduled maintenance............................................................................................................................... 455
Maintenance kits........................................................................................................................................................455
Parts catalog............................................................................................. 458
Legend...............................................................................................................................................................458
Assembly 1: Covers.........................................................................................................................................459
Assembly 2: T650, T652, and T654 operator panel.............................................................................463
Assembly 3: T656 Operator panel, MPF and smart card.....................................................................465
Assembly 4: Drive motor assemblies and duplex.................................................................................. 467
Assembly 5: Media path and ducts............................................................................................................. 471
Assembly 6: Printhead, charge, and transfer...........................................................................................473
Assembly 7: Pick arm assembly, trays, and MPF.................................................................................... 476
Assembly 8: LVPS, fuser, and electrical cables 1.................................................................................... 479
Assembly 9: HVPS, system card, and electrical cables 2..................................................................... 481
Assembly 10: 250-sheet option tray assembly....................................................................................... 483
Assembly 11: 550-sheet option tray assembly........................................................................................ 485
Assembly 12: HCIT Sheet option tray assembly..................................................................................... 487
Assembly 13: SFP stapler assembly 1........................................................................................................ 489
Assembly 14: SFP stapler assembly 2........................................................................................................ 491
Assembly 15: SFP stapler assembly 3....................................................................................................... 493
Assembly 16: 5-bin mailbox 1....................................................................................................................... 495
Assembly 17: 5-bin mailbox 2.......................................................................................................................497
Assembly 18: High capacity stacker...........................................................................................................499
Assembly 19: Output expander....................................................................................................................501
Assembly 20: Envelope feeder and external duplex............................................................................503
Assembly 21: RFID UHF Option assembly............................................................................................... 505
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Assembly 22: Miscellaneous 1.....................................................................................................................507
Assembly 23: Miscellaneous 2................................................................................................................... 509
Assembly 24: Power cords.............................................................................................................................511
Assembly 25: Universal trays and accessories........................................................................................513
Appendix A: Printer specifications......................................................... 515
Power consumption........................................................................................................................................ 515
Product power consumption...................................................................................................................................515
Power Saver.................................................................................................................................................................515
O mode.......................................................................................................................................................................515
Total energy usage ....................................................................................................................................................516
Noise emission levels.....................................................................................................................................516
Temperature information............................................................................................................................... 516
Appendix B: Options and features..........................................................517
Available internal options.............................................................................................................................. 517
Media handling options..................................................................................................................................517
Appendix C: Theory of operation............................................................519
POR sequence..................................................................................................................................................519
Printer control................................................................................................................................................... 519
Printer theory.................................................................................................................................................... 519
T650 with duplex, paper path, rolls, and sensors .............................................................................................519
T652 and T654 with duplex, paper path, rolls, and sensors........................................................................ 520
Functions of main components ..............................................................................................................................521
Media tray assembly.................................................................................................................................................522
MPF ...............................................................................................................................................................................524
Registration .................................................................................................................................................................526
Transfer ........................................................................................................................................................................527
Polygon printhead assembly..................................................................................................................................527
Oscillating printhead assembly .............................................................................................................................529
Fuser.............................................................................................................................................................................530
Fuser components .....................................................................................................................................................531
Fuser unit assembly (types 1 and 2)......................................................................................................................533
Exit.................................................................................................................................................................................534
Drive..............................................................................................................................................................................535
Electrical components and controller ..................................................................................................................536
Printhead control .......................................................................................................................................................537
Fuser control...............................................................................................................................................................537
Xerographic and print cartridge components ...................................................................................................538
High capacity input tray (HCIT) tray assembly...................................................................................................544
250-sheet/550-sheet tray assembly....................................................................................................................545
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Paper path, rolls, and sensors................................................................................................................................549
Duplex ..........................................................................................................................................................................552
Appendix D: Acronyms............................................................................557
Acronyms.......................................................................................................................................................... 557
Index.......................................................................................................... 559
Part number index....................................................................................569
Part name index........................................................................................ 581
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Notices and safety information
Laser notices
Laser notice
The printer is
certified
in the U.S. to conform to the requirements of DHHS 21 CFR, Chapter I, Subchapter J for
Class I (1) laser products, and elsewhere is certified as a Class I laser product conforming to the requirements
of IEC 60825-1.
Class I laser products are not considered to be hazardous. The printer contains internally a Class IIIb (3b) laser
that is nominally a 5 milliwatt gallium arsenide laser operating in the wavelength of 770-795 nanometers. The
laser system and printer are designed so there is never any human access to laser radiation above a Class I
level during normal operation, user maintenance, or prescribed service condition.
Laser-Hinweis
Der Drucker wurde in den USA zertifiziert und entspricht den DHHS-Vorschriften 21 CFR, Kapitel I, Unterkapitel J
für Laserprodukte der Klasse I (1); andernorts ist er als Laserprodukt der Klasse I
zertifiziert,
das den IEC 60825-1-
Anforderungen entspricht.
Laserprodukte der Klasse I werden nicht als gefährlich eingestuft. Der Drucker enthält im Inneren einen Laser
der Klasse IIIb (3b), und zwar einen 5-Milliwatt-Gallium-Arsenid-Laser, der im Wellenlängenbereich von 770 bis
795 Nanometern arbeitet. Das Lasersystem und der Drucker sind so konstruiert, dass unter normalen
Betriebsbedingungen, bei der Wartung durch den Benutzer oder bei den vorgeschriebenen
Wartungsbedingungen Menschen keiner Laserstrahlung ausgesetzt sind, die die Werte für Klasse I
überschreitet.
Avis relatif à l'utilisation du laser
L'imprimante est certifiée conforme aux exigences de la réglementation des Etats-Unis relative aux produits
laser (DHHS 21 CFR, Chapter I, Subchapter J for Class I (1)). Pour les autres pays, elle est certifiée conforme aux
exigences des normes IEC 60825-1 relatives aux produits laser de classe I.
Les produits laser de Classe I ne sont pas considérés comme dangereux. L'imprimante contient un laser de
classe IIIb (3b), laser arséniure de gallium 7 milliwatts opérant sur une longueur d'onde de l'ordre de 770 à
795 nanomètres. Le système laser ainsi que l'imprimante ont été conçus de manière à ce que personne ne soit
exposé à des rayonnements laser dépassant le niveau de classe I dans le cadre d'un fonctionnement normal,
de l'entretien par l'utilisateur ou de la maintenance.
Avvertenze sui prodotti laser
La stampante è
certificata
negli Stati Uniti come stampante conforme ai requisiti DHHS 21 CFR, Capitolo I,
Sottocapitolo J per i prodotti laser di Classe I (1), mentre in altri paesi è certificata come prodotto laser di Classe
I conforme ai requisiti IEC 60825-1.
I prodotti laser di Classe I non sono considerati pericolosi. La stampante contiene un laser di Classe IIIb (3b),
che è nominalmente un laser ad arseniuro di gallio a 5 milliwatt funzionante a una lunghezza d'onda di 770-795
nanometri. Il sistema laser e la stampante sono stati progettati in modo da impedire l'esposizione a radiazioni
laser superiori al livello previsto dalla Classe I durante le normali operazioni di stampa, manutenzione o
assistenza.
4062
Notices and safety information
17
Aviso de láser
Esta impresora se ha certificado en EE. UU. de conformidad con los requisitos de DHHS 21 CFR, capítulo I,
subcapítulo J, para los productos láser de Clase I (1), y en otros países está certificada como un producto láser
de Clase I de acuerdo con los requisitos de IEC 60825-1.
Los productos láser de Clase I no se consideran peligrosos. La impresora contiene un láser interno de Clase
IIIb (3b) que nominalmente es un láser de arseniuro de galio de 5 milivatios que funciona en una longitud de
onda de 770-795 nanómetros. El sistema láser y la impresora se han diseñado para que ningún individuo
acceda nunca a las radiaciones láser por encima del nivel de Clase I durante su uso normal, ni en tareas de
mantenimiento o intervenciones de servicio técnico prescritas.
Aviso sobre laser
A impressora foi certificada nos EUA por estar em conformidade com os requisitos do DHHS 21 CFR, capítulo
I, subcapítulo J, para produtos a laser de Classe I (1) e, nos demais países, foi certificada como produto a laser
de Classe I em conformidade com os requisitos da IEC 60825-1.
Os produtos a laser de Classe I não são considerados perigosos. A impressora contém, internamente, um laser
de Classe IIIb (3b) que é um laser de arsenieto de gálio de 5 miliwatts operando no comprimento de onda de
770-795 nanômetros. O sistema do laser e a impressora foram projetados para que jamais haja acesso humano
à radiação do laser acima do nível da Classe I durante a operação normal ou a manutenção pelo usuário ou
sob as condições de manutenção prescritas.
Laserinformatie
Deze printer is in de Verenigde Staten gecertificeerd als een product dat voldoet aan de vereisten van DHHS
21 CFR, hoofdstuk 1, paragraaf J voor laserproducten van klasse I (1). Elders is de printer gecertificeerd als een
laserproduct van klasse I dat voldoet aan de vereisten van IEC 60825-1.
Laserproducten van klasse I worden geacht geen gevaar op te leveren. De printer bevat intern een laser van
klasse IIIb (3b), een galliumarsenide laser met een nominaal vermogen van 5 milliwatt en een golflengtebereik
van 770-795 nanometer. Het lasersysteem en de printer zijn zodanig ontworpen dat gebruikers nooit blootstaan
aan laserstraling die hoger is dan het toegestane niveau voor klasse I-apparaten, tijdens normaal gebruik,
onderhoudswerkzaamheden door de gebruiker of voorgeschreven servicewerkzaamheden.
Lasererklæring
Denne printer er certificeret i USA i henhold til kravene i DHHS 21 CFR, afsnit I, underafsnit J, for Klasse I-
laserprodukter (1) og certificeret andetsteds som et Klasse I-laserprodukt i henhold til kravene i IEC 60825-1.
Klasse I-laserprodukter anses ikke for at være farlige. Printeren indeholder internt en klasse IIIb (3b)-laser, der
nominelt er en 5 milliwatt galliumarsenid-laser, som fungerer i bølgelængdeområdet 770-795 nanometer.
Lasersystemet og printeren er udviklet på en sådan måde, at der ikke er en direkte laserstråling, der overskrider
Klasse I-niveauet under normal brug, brugers vedligeholdelse eller de foreskrevne servicebetingelser.
Laserilmoitus
Tämä tulostin on sertifioitu Yhdysvalloissa DHHS 21 CFR, Chapter I, Subchapter J -standardin mukaiseksi luokan
I (1) -lasertuotteeksi ja muualla IEC 60825-1 -standardin mukaiseksi luokan I lasertuotteeksi.
4062
Notices and safety information
18
Luokan I lasertuotteita ei pidetä haitallisina. Tulostimen sisällä on luokan IIIb (3b) laser, joka on nimellisteholtaan
5 mW:n galliumarsenidilaser ja toimii 770–795 nanometrin aallonpituuksilla. Laserjärjestelmä ja tulostin ovat
rakenteeltaan sellaisia, että käyttäjä ei joudu alttiiksi luokkaa 1 suuremmalle säteilylle normaalin käytön,
ylläpidon tai huollon aikana.
Lasermeddelande
Skrivaren är certifierad i USA enligt kraven i DHHS 21 CFR, avsnitt I, underavsnitt J för laserprodukter av klass
I (1) och i andra länder är den
certifierad
som en laserprodukt av klass I som uppfyller kraven i IEC 60825-1.
Laserprodukter av klass I anses inte vara skadliga. Skrivaren innehåller en klass IIIb (3b)-laser, vilket är en 5 mW
galliumarseniklaser som arbetar inom en våglängd på 770–795 nm. Lasersystemet och skrivaren är utformade
så att människor aldrig utsätts för laserstrålning över klass I-nivå under normala förhållanden vid användning,
underhåll eller service.
Lasermerknad
Skriveren er
sertifisert
i USA for samsvar med kravene i DHHS 21 CFR, kapittel I, underkapittel J for
laserprodukter av klasse I (1), og er andre steder sertifisert som et laserprodukt av klasse I som samsvarer med
kravene i IEC 60825-1.
Laserprodukter av klasse I anses ikke som helseskadelige. Skriveren inneholder en intern laser av klasse IIIb
(3b) som nominelt er en 5 milliwatt galliumarsenid-laser, og som opererer i bølgelengder på 770-795 nanometer.
Lasersystemet og skriveren er utformet slik at mennesker ikke utsettes for laserstråling utover nivået i klasse
I under normal drift, vedlikehold eller foreskrevet service.
Avís sobre el làser
Als EUA, la impressora està certificada de conformitat amb els requisits del capítol I, apartat J del CFR 21 del
Departament de Salut i Serveis Humans per a productes làser de classe I (1) i a la resta de països està certificada
com a producte làser de classe I d'acord amb els requisits de la norma IEC 60825-1.
Els productes làser de classe I no es consideren perillosos. A l'interior de la impressora hi ha un làser de classe
IIIb (3b) que nominalment es un arsenur de galió de 5 mil·liwatts que funciona a una longitud d'ona de 770-795
nanòmetres. El sistema làser y la impressora s'han dissenyat amb l'objectiu d'impedir l'accés humà de la radiació
làser superior al nivell de classe I durant un funcionament normal, el manteniment per part de l'usuari o les
condicions de servei prescrites.
レーザーに関する通知
本機は、米国においてクラス I（1）レーザー製品に対する DHHS 21 CFR、Chapter I、Subchapter J の要件
に準拠し、その他の国では IEC 60825-1 の要件に準拠するクラス I レーザー製品として認可されています。
クラス I レーザー製品は、危険性がないとみなされています。 本機には、クラス IIIb（3b）レーザーが内蔵
されています。これは、770 ～ 775 ナノメートルの波長で動作する定格 5 ミリワットのガリウムヒ素レー
ザーです。 レーザーシステムとプリンタは、通常の操作、ユーザーによるメンテナンス、または所定のサ
ービス条件の下で、ユーザーがクラス I レベルを超えるレーザー放射に絶対にさらされないように設計され
ています。
레이저 관련 공지
이 프린터는 미국에서 DHHS 21 CFR, Chapter I, Subchapter J의 요구 사항을 준수하는 클래스 I(1) 레이저 제품
으로 승인되었으며 이외 지역에서 IEC 60825-1의 요구 사항을 준수하는 클래스 I 레이저 제품으로 승인되었습
니다.
4062
Notices and safety information
19
Class I 레이저 제품은 위험한 제품으로 간주되지 않습니다. 프린터에는 770-795 나노미터의 파장 영역에서 작
동하는 공칭 5밀리와트 갈륨 비소 레이저인 클래스 IIIb(3b) 레이저가 내부에 포함되어 있습니다. 레이저 시스
템과 프린터는 정상적인 작동, 사용자 유지 관리 또는 사전 설명된 서비스 조건에는 사람에게 클래스 I 수준 이
상의 레이저 방사가 노출되지 않도록 설계되었습니다.
激光注意事项
本打印机在美国认证合乎 DHHS 21 CFR Chapter I，Subchapter J 对分类 I（1）激光产品的标准，而在其他地
区则被认证是合乎 IEC 60825-1 的分类 I 激光产品。
一般认为分类 I 激光产品不具有危险性。本打印机内部含有分类 IIIb（3b）的激光，在操作过程中会产生额定
5 毫瓦的砷化镓激光，其波长范围在 770-795nm 之间。本激光系统及打印机的设计，在一般操作、使用者维
护或规定内的维修情况下，不会使人体接触分类 I 以上等级的辐射。
雷射聲明
本印表機係經過美國核可，符合 DHHS 21 CFR，Chapter I，Subchapter J 規定的 I (1) 級雷射產品激光注意事
项；在美國以外的地區，為符合 IEC 60825-1 規定的 I 級雷射產品。
根據 I 級雷射產品的規定，這類產品不會對人體造成傷害。本機所採用之 IIIb (3b) 級雷射只會產生 5 百萬分之
一瓦特 (milliwatt)、波長 770 至 795 億分之一米 (nanometer) 的鎵砷放射線 (gallium arsenide laser)。使用者只
要以正確的方法操作及維護保養，並依照先前所述之維修方式進行修護，此印表機與其雷射系統絕不會產生 I
級以上的放射線，而對人體造成傷害。
Safety information
Safety information
• The safety of this product is based on testing and approvals of the original design and specific components.
The manufacturer is not responsible for safety in the event of use of unauthorized replacement parts.
• The maintenance information for this product has been prepared for use by a professional service person
and is not intended to be used by others.
• There may be an increased risk of electric shock and personal injury during disassembly and servicing of
this product. Professional service personnel should understand this and take necessary precautions.
CAUTION—POTENTIAL INJURY
The lithium battery in this product is not intended to be replaced. There is a danger of explosion if
a lithium battery is incorrectly replaced. Do not recharge, disassemble, or incinerate a lithium battery.
Discard used lithium batteries according to the manufacturer's instructions and local regulations.
Consignes de sécurité
• La sécurité de ce produit repose sur des tests et des agréations portant sur sa conception d'origine et sur
des composants particuliers. Le fabricant n'assume aucune responsabilité concernant la sécurité en cas
d'utilisation de pièces de rechange non agréées.
• Les consignes d'entretien et de réparation de ce produit s'adressent uniquement à un personnel de
maintenance
qualifié.
• Le démontage et l'entretien de ce produit pouvant présenter certains risques électriques, le personnel
d'entretien qualifié devra prendre toutes les précautions nécessaires.
4062
Notices and safety information
20
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