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Lexmark T654 Service Manual - Page 25

General information, Maintenance approach, Machine type, Model, Configuration - t654dn

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4062-XXX 1. General information The Lexmark™ laser printers are letter-quality page printers designed to attach to personal computers and to most computer networks. The Lexmark laser printers are available in the following models: Machine type 4062-01A 4062-21A 4062-23A 4062-41A 4062-43A 4062-630 Model T650n T652n T652dn T654n T654dn T656dne Configuration Network Network Network Network Network Network Maintenance approach The diagnostic information in this manual leads you to the correct field replaceable unit (FRU) or part. Use the service error codes, user status messages, user error messages, service checks, and diagnostic aids to determine the printer problem and repair the failure. After you complete the repair, perform tests as needed to verify the repair. See "Start" on page 2-1. General information 1-1

Section	Page
Table of contents	3
Notices and safety information	15
Laser notice	15
Laser	15
Avis relatif à l’utilisation de laser	15
Avvertenze sui prodotti laser	15
Avisos sobre el láser	16
Declaração sobre Laser	16
Laserinformatie	16
Lasermeddelelse	16
Laserilmoitus	17
Huomautus laserlaitteesta	17
Laser-notis	17
Laser-melding	17
Avís sobre el Làser	18
Lithium warning	21
Consignes de sécurité	21
Norme di sicurezza	21
Sicherheitshinweise	22
Pautas de Seguridad	22
Informações de Segurança	22
Informació de Seguretat	23
Preface	24
1. General information	25
Maintenance approach	25
Options	26
Available internal options	26
Media handling options	26
Printer configurations	27
Supported paper sizes, types, and weights	30
Tools required	32
Acronyms	33
2. Diagnostic information	35
Start	35
Confirm the installation status	36
Power-on Reset sequence	36
Entering Diagnostics mode	36
User attendance messages	37
Error code table 1	48
Service checks	160
Sensor (input) service check	160
Sensor (fuser output) service check	160
Sensor (narrow media) service check	161
Sensor (duplex input) service check	161
Sensor (duplex input) service check (external duplex only)	162
Sensor (duplex exit) service check (external duplex only)	162
Sensor (pass through) service check	163
Sensor (envelope feeder empty) service check	163
Sensor (input) late jam service check.	163
Sensor (input) lingering jam service check.	166
Sensor (input) early jam service check	167
Sensor (input) static jam service check	169
Sensor (fuser output) late jam service check.	169
Sensor (fuser output) lingering jam service check.	171
Sensor (fuser output) static jam service check	172
Sensor (narrow media) late jam service check.	173
Sensor (narrow media) static jam service check	174
Sensor (duplex input) late jam service check.	175
Sensor (duplex input) lingering jam service check.	176
Sensor (duplex input) static jam service check.	178
Sensor (pass through) late jam service check	179
Sensor (pass through) lingering jam service check.	180
Sensor (pass through) static jam service check	181
Sensor (stapler pass through) late jam service check	182
Sensor (stapler pass through) lingering jam service check	183
Sensor (stapler pass through) static jam service check	183
Sensor (output pass through) late jam service check	184
Sensor (output pass through) lingering jam service check	185
Sensor (output pass through) static jam service check	186
Sensor (mailbox empty) late jam service check	187
Sensor (mailbox empty) lingering jam service check	188
Sensor (mailbox empty) static jam service check	188
Sensor (toner empty) service check	189
NVRAM mismatch failure (950.00 through 950.29) service check	189
Image quality trouble	191
Printer Related Troubleshooting	191
Image Quality	192
Network service check	211
3. Diagnostic aids	213
Understanding the printer control panel (models T650, T652, and T654)	213
Accessing service menus (models T650, T652, and T654)	214
Diagnostics mode (models T650, T652, and T654)	215
Entering Diagnostics mode (models T650, T652, and T654)	215
Available tests	215
Exiting Diagnostics mode (models T650, T652, and T654)	217
REGISTRATION	217
PRINT TESTS	219
HARDWARE TESTS	220
DUPLEX TESTS	224
INPUT TRAY TESTS	226
OUTPUT BIN TESTS	227
StapleSmart FINISHER TESTS	230
BASE SENSOR TEST	231
PRINTER SETUP	231
EP SETUP	233
REPORTS	235
EVENT LOG	235
EXIT DIAGNOSTICS (models T650, T652, and T654)	236
Configuration menu (CONFIG MENU) (models T650, T652, and T654)	237
Entering Configuration Menu (models T650, T652, and T654)	237
Available menus	237
Maintenance page count (Maint Cnt Value)	237
Maintenance page counter reset (Reset Cnt)	238
Print quality pages (Prt Quality Pgs)	238
Reports	238
SIZE SENSING	239
Panel Menus	239
PPDS Emulation	239
Demo Mode	239
Factory Defaults	240
LES Applications	240
Energy Conserve	240
Paper Prompts	240
Env Prompts	240
Action for Prompts	240
Font Sharpening	240
Wiper Messages	240
Clear Custom Status	240
Best Speed	241
Exit Config Menu (models T650, T652, and T654)	241
Understanding the printer control panel (model T656)	241
Accessing service menus (model T656)	242
Diagnostics Menu (model T656)	243
Entering Diagnostics Menu (model T656)	243
Available tests	243
Registration (printer)	245
PRINT TESTS	247
HARDWARE TESTS	248
DUPLEX TESTS	250
INPUT TRAY TESTS	252
OUTPUT BIN TESTS	253
BASE SENSOR TEST	254
DEVICE TESTS	255
PRINTER SETUP	256
EP SETUP	257
REPORTS	259
EVENT LOG	259
Configuration menu (CONFIG MENU) (model T656)	261
Entering Configuration Menu (model T656)	261
Available menus	261
Maintenance Counter Value	261
Reset Maintenance Counter	262
Print Quality Pages	263
Reports	263
SIZE SENSING	264
Panel Menus	264
PPDS Emulation	264
Factory Defaults	266
Energy Conserve	266
Paper Prompts	267
Envelope Prompts	267
Action for Prompts	267
Jobs On Disk	267
Disk Encryption	268
Wipe Disk	269
Font Sharpening	269
Require Standby	269
LES Applications	270
Key Repeat Initial Delay	270
Key Repeat Rate	270
Wiper Message	270
Clear Custom Status	270
USB speed	271
Exit Configuration Menu (model T656)	271
Printer overview	272
Printer theory	273
Model T650 with duplex, paper path, rolls, and sensors	273
Models T652 and T654 paper path rolls and sensors	274
Functions of main components	274
Media tray assembly	275
Multi-purpose feeder (MPF)	277
Supported paper sizes, types, and weights	278
Registration	279
Transfer	280
Polygon printhead assembly	281
Oscillating printhead assembly	283
Fuser	284
Fuser components	284
Fuser unit assembly (type 1 and type 2)	285
Exit	286
Drive	287
Electrical components and controller	288
Control	289
Printhead control	289
Fuser control	289
Xerographic and print cartridge components	290
High Capacity Input Tray (HCIT) tray assembly	296
250-sheet/550-sheet tray assembly	297
Model T650 paper path, rolls, and sensors	301
Models T652 and T654 paper path, rolls, and sensors	302
Media tray assembly	303
Duplex	305
Model T650 duplex paper path	305
Models T652 and T654 duplex paper path	306
Understanding jam numbers and locations	308
200 and 201 paper jams	308
202 and 203 paper jams	309
230 paper jam	310
231-239 paper jams (optional external duplex unit)	312
241–245 paper jams	313
250 paper jam	314
260 paper jam	315
271–279 paper jams	315
280 paper jam	316
281 paper jam	317
282 paper jam	317
283 staple jam	318
Security Reset Jumper	320
Security Reset Jumper	320
4. Repair Information	323
Handling ESD-sensitive parts	323
Adjustments	324
Polygon and Oscillating printhead mechanical registration adjustment	324
Oscillating printhead assembly electronic adjustment	325
Alignment assembly adjustment	326
Fuser solenoid adjustment	328
Gap adjustment	328
Removals	329
Replacement note: To replace a removed part, reverse the order of removal unless noted otherwise.	329
Access door removal (T650, T652, T654)	330
Alignment assembly removal (T650, T652, T654)	330
Connection access cover, rear removal (T650, T652, T654)	333
Connection bezel assembly, rear removal (T650)	333
Connection bezel assembly, rear removal (T652, T654)	334
Cover assembly, rear lower removal (T650)	335
Cover assembly, rear lower (T652, T654)	335
Charge roll assembly removal (T650, T652, T654)	336
Door assembly, rear removal (T650, T652, T654)	337
Duplex guide assembly, rear removal (T652, T654)	337
Duplex assembly removal (T652, T654)	338
Duplex cooling fan removal (T652, T654)	340
Duplex drive motor assembly removal (T652, T654)	341
Duplex input sensor assembly removal (T652, T654)	342
Duplex guide assembly, front removal (T652, T654)	343
Fuser access door assembly removal (T650, T652, T654)	344
Fuser drive release linkage removal (T650, T652, T654)	345
Fuser unit assembly removal (T650, T652, T654)	345
Fuser wiper cover assembly removal (T650, T652, T654)	346
HVPS card assembly removal (T650, T652, T654)	346
Inner deflector removal (T650, T652, T654)	347
Laser cover removal (T650, T652, T654)	349
LCD screen bezel removal (T650, T652, T654)	350
LVPS card assembly removal (T650)	351
LVPS card assembly removal (T652, T654)	353
Main cooling fan removal (T650, T652, T654)	354
Main drive motor assembly removal (T650, T652, T654)	356
Media out actuator removal (T650, T652, T654)	357
Media support removal (T650, T652, T654)	358
Media turn guide removal (T650, T652, T654)	358
MPF cam gear removal (T650, T652, T654)	359
MPF lift plate assembly removal (T650, T652, T654)	359
MPF media out actuator removal (T650, T652, T654)	360
MPF pick roll assembly removal (T650, T652, T654)	360
MPF pick solenoid assembly removal (T650, T652, T654)	361
MPF tray door assembly removal (T650, T652, T654)	363
Operator panel latch assembly removal (T650, T652, T654)	365
Operator panel door assembly removal (T650, T652, T654)	366
Operator panel hinge assembly, left removal (T650, T652, T654)	367
Operator panel hinge assembly, right removal (T650, T652, T654)	369
Operator panel door assembly removal (models X651, X652, X654, and X656)	371
Operator panel cover latch assembly removal (models X651, X652, X654, and X656)	374
Option drive shaft removal (T650, T652, T654)	374
Output cover assembly removal (T650, T652, T654)	376
Pick arm assembly removal (T650, T652, T654)	376
Pick roll assembly removal (T650, T652, T654)	379
Print cartridge cooling fan removal (T650, T652, T654)	379
Print cartridge clamp assembly removal (T650, T652, T654)	380
Print cartridge ID connector assembly removal (T650, T652, T654)	381
Printhead assembly removal (T650)	382
Printhead assembly removal (T652, T654)	383
Redrive assembly removal (T650, T652, T654)	384
Redrive motor assembly removal (T652, T654)	385
Side cover, left removal (T650)	387
Side cover, left removal (T652 and T654)	388
Side cover, right removal (T650)	389
Side cover, right removal (T652, T654)	390
Sensor (duplex input) removal (T652, T654)	390
Sensor (media level) removal (T650, T652, T654)	392
Sensor (media out) removal (T650, T652, T654)	392
Sensor (toner empty) removal (T650, T652, T654)	393
Sensor (input) removal (T650, T652, T654)	393
Sensor shield assembly removal (T650, T652, T654)	394
Sensor (standard bin exit) removal (T650, T652, T654)	395
Sensor (toner density) removal (T650, T652, T654)	395
Standard bin actuator assembly removal (T650, T652, T654)	395
Switch (media size) assembly removal (T650, T652, T654)	396
System card assembly removal (T650, T652, T654, T656)	398
Transfer roll assembly removal (T650, T652, T654)	400
Transfer roll bracket assembly, left removal (T650, T652, T654)	401
Transfer roll bracket assembly, right removal (T650, T652, T654)	402
Transfer deflector removal (T650, T652, T654)	402
Tray roller catch assembly removal (T650, T652, T654)	403
Option removals	405
5-bin mailbox rear door assembly removal	406
5-bin mailbox left outer cover removal	407
5-bin mailbox left inner cover removal	407
5-bin mailbox right outer cover removal	408
5-bin mailbox right inner cover removal	409
5-bin mailbox top cover removal	410
5-bin mailbox media bin full actuator removal	411
5-bin mailbox sensor (pass through) removal	412
5-bin mailbox sensor (media bin empty) removal	413
5-bin mailbox controller card assembly removal	414
5-bin mailbox static brush mylar assembly removal	415
5-bin mailbox media bin fifth deflector removal	416
5-bin mailbox media bin first through fourth deflector removal	417
5-bin mailbox media bin extension assembly removal	418
5-bin mailbox deflector gate solenoid removal	418
5-bin mailbox transport solenoid removal	420
5-bin mailbox sensor (deflector gate HP) removal	421
250-sheet option tray assembly	423
250-sheet media tray assembly removal	423
250-sheet pick arm bracket assembly removal	424
250-sheet media out actuator removal	426
250-sheet frame assembly removal	426
250-sheet controller card assembly removal	428
550-sheet option tray assembly	429
550-sheet media tray assembly removal	429
550-sheet pick arm bracket assembly removal	430
550-sheet bellcrank recoil spring removal	431
550-sheet frame assembly removal	431
550-sheet controller card assembly removal	433
550-sheet option drive shaft with spring removal	435
Anti-tip latch assembly removal	435
High capacity input tray (HCIT)	436
High capacity input tray (HCIT) media tray assembly removal	437
High capacity input tray (HCIT) tray cover, front removal	438
High capacity input tray (HCIT) cover, rear removal	440
High capacity input tray (HCIT) cover, right removal	442
High capacity input tray (HCIT) cover, left removal	444
High capacity input tray (HCIT) anti-tip latch assembly removal	445
High capacity input tray (HCIT) drawer slide assembly removal	446
High capacity input tray (HCIT) tray lift drive motor assembly removal	447
High capacity input tray (HCIT) controller card assembly removal	448
High capacity input tray (HCIT) media size actuator assembly removal	449
High capacity input tray (HCIT) pick arm bracket assembly removal	452
High capacity input tray (HCIT) tray closed latch with spring removal	454
High capacity stacker rear door assembly removal	454
High capacity stacker right cover removal	456
High capacity stacker left cover removal	457
High capacity stacker media output bin assembly removal	458
High capacity stacker controller card cover panel removal	459
High capacity stacker switch (media bin HP) removal	460
High capacity stacker sensor (media bin full) assembly removal	461
High capacity stacker sensor (media bin full) bracket assembly removal	461
High capacity stacker controller card assembly (upper and lower) removal	462
High capacity stacker right frame removal	463
High capacity stacker left frame removal	464
High capacity stacker upper deflector gate removal	465
High capacity stacker sensor (pass through) removal	466
High capacity stacker left mounting bracket removal	468
High capacity stacker sensor (deflector gate HP) removal	469
Installing / Removing the RFID UHF option	470
Lower interface cable assembly removal	478
Media size actuator removal	479
Media tray catch spring removal	480
Media out actuator removal (models T652 and T654)	480
Media size actuator removal	481
Media tray catch spring removal	481
Media tray roller catch assembly removal	481
Output expander rear door assembly removal	483
Output expander left outer cover removal	483
Output expander left inner cover removal	484
Output expander right outer cover removal	484
Output expander right inner cover removal	485
Output expander media bin latch (left and right) removal	485
Output expander media output bin assembly removal	486
Output expander media bin full actuator removal	486
Output expander sensors (media bin full) assembly removal	487
Output expander sensor (media bin full) bracket assembly removal	488
Output expander controller card cover panel removal	488
Output expander controller card removal	490
Output expander sensor (pass through) removal	491
Output expander deflector gate removal	492
Output expander sensor (deflector gate HP) removal	493
SFP stapler assembly rear door assembly removal	494
SFP stapler assembly right cover removal	494
SFP stapler assembly left cover removal	495
SFP stapler assembly top cover removal	496
SFP stapler assembly handle cover removal	497
SFP stapler assembly LED sensor cover removal	498
SFP stapler assembly sensor (finisher bin media present) removal	499
SFP stapler assembly standard output bin LED and LED clear lens removal	500
SFP stapler assembly tamper drive belt removal	501
SFP stapler assembly tamper drive motor assembly removal	502
SFP stapler assembly media stack flap and media stack flap actuator removal	503
SFP stapler assembly stapler unit assembly removal	504
SFP stapler assembly paddle drive motor assembly removal	505
SFP stapler assembly sensor (media stack) removal	506
SFP stapler assembly sensor (paddle HP) removal	507
SFP stapler assembly sensor (stapler access door interlock) removal	508
SFP stapler assembly sensor (tamper HP left and right) removal	509
SFP stapler assembly sensor (bin full send) removal	510
SFP stapler assembly sensor (bin full receive) removal	511
SFP stapler assembly sensor (media in stapler) removal	511
SFP stapler assembly sensor (deflector HP) removal	512
Stapler/stacker controller card assembly removal	514
Sensor (HCIT tray raised HP) with cable assembly removal	514
Sensor (HCIT pass through) with cable removal	517
Sensor (pass through) with cable removal	518
Sensor (pass through) with cable removal	518
Tray roller catch assembly removal	518
Tray roller catch assembly removal	519
Upper interface cable assembly removal	519
5. Connector locations and connections	521
Connections	521
6. Preventive maintenance	523
Safety inspection guide	523
Lubrication specifications	523
Individual maintenance part expected life	523
Scheduled maintenance	524
Maintenance kit	524
7. Parts catalog	525
How to use this parts catalog	525
Assembly 1: Covers	526
Assembly 2: T650, T652, and T654 Operator panel	528
Assembly 3: T656dne Operator panel, MPF and smart card	530
Assembly 4: Drive motor assemblies and duplex	532
Assembly 5: Media path and ducts	534
Assembly 6: Printhead, charge, and transfer	536
Assembly 7: Pick arm assembly, trays, and MPF	538
Assembly 8: LVPS, fuser and electrical cables 1	540
Assembly 9: HVPS, system card, and electrical cables 2	542
Assembly 10: 250 Sheet option tray assembly	544
Assembly 11: 550 Sheet option tray assembly	546
Assembly 12: HCIT Sheet option tray assembly	548
Assembly 13: SFP stapler assembly #1	550
Assembly 14: SFP stapler assembly #2	552
Assembly 15: SFP stapler assembly #3	554
Assembly 16: SFP stapler assembly #4	556
Assembly 17: 5-bin mailbox #1	558
Assembly 18: 5-bin mailbox #2io	560
Assembly 19: High capacity stacker	562
Assembly 20: Output expander	564
Assembly 21: Envelope feeder and external duplex	566
Assembly 22: RFID UHF Option assembly	568
Assembly 23: Miscellaneous	569
Assembly 24: Power cords	571
Assembly 25: Universal trays and accessories	572
Index	573
Part number index	577
Print defects guide	585