Contacting Customer Support.....194

Notices....195

Product information.....195 Edition notice.....195 Power consumption.....199

Index....210

Safety information
Connect the power cord to an electrical outlet that is near the product and easily accessible. Do not place or use this product near water or wet locations. CAUTIONPOTENTIAL INJURY: This product uses a laser. Use of controls or adjustments or performance of procedures other than those specified herein may result in hazardous radiation exposure. This product uses a printing process that heats the print media, and the heat may cause the media to release emissions. You must understand the section in your operating instructions that discusses the guidelines for selecting print media to avoid the possibility of harmful emissions. Use care when you replace a lithium battery. CAUTIONPOTENTIAL INJURY: There is a danger of explosion if a lithium battery is incorrectly replaced. Replace it only with the same or an equivalent type of lithium battery. Do not recharge, disassemble, or incinerate a lithium battery. Discard used batteries according to the manufacturer's instructions and local regulations. CAUTIONHOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching. CAUTIONPOTENTIAL INJURY: The printer weight is greater than 18 kg (40 lb) and requires two or more trained personnel to move it safely. CAUTIONPOTENTIAL INJURY: Before moving the printer, follow these guidelines to avoid personal injury or printer damage:
Turn the printer off using the power switch, and then unplug the power cord from the wall outlet. Disconnect all cords and cables from the printer before moving it. Lift the printer off the optional drawer, and set it aside instead of trying to lift the drawer and printer at the same
time. Note: Use the handholds located on both sides of the printer to lift it off the optional drawer. Use only the power cord provided with this product or the manufacturer's authorized replacement. Use only the telecommunications (RJ-11) cord provided with this product or a 26 AWG or larger replacement when connecting this product to the public switched telephone network. CAUTIONSHOCK HAZARD: If you are accessing the system board or installing optional hardware or memory devices sometime after setting up the printer, then turn the printer off, and unplug the power cord from the wall outlet before continuing. If you have any other devices attached to the printer, then turn them off as well, and unplug any cables going into the printer. CAUTIONSHOCK HAZARD: Make sure that all external connections (such as Ethernet and telephone system connections) are properly installed in their marked plug-in ports. This product is designed, tested, and approved to meet strict global safety standards with the use of specific manufacturer's components. The safety features of some parts may not always be obvious. The manufacturer is not responsible for the use of other replacement parts. CAUTIONPOTENTIAL INJURY: Do not cut, twist, bind, crush, or place heavy objects on the power cord. Do not subject the power cord to abrasion or stress. Do not pinch the power cord between objects such as furniture and walls. If any of these things happen, a risk of fire or electrical shock results. Inspect the power cord regularly for signs of such problems. Remove the power cord from the electrical outlet before inspecting it.

Refer service or repairs, other than those described in the user documentation, to a professional service person. CAUTIONSHOCK HAZARD: To avoid the risk of electric shock when cleaning the exterior of the printer, unplug the power cord from the wall outlet and disconnect all cables from the printer before proceeding. CAUTIONSHOCK HAZARD: Do not use the fax feature during a lightning storm. Do not set up this product or make any electrical or cabling connections, such as the fax feature, power cord, or telephone, during a lightning storm. CAUTIONTIPPING HAZARD: Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a high-capacity input tray, a duplex unit and an input option, or more than one input option. If you purchased a multifunction printer (MFP) that scans, copies, and faxes, you may need additional furniture. For more information, see www.lexmark.com/multifunctionprinters. SAVE THESE INSTRUCTIONS.
Learning about the printer
Finding information about the printer

Setup information

Description Where to find The Setup information gives you instructions for setting You can find the Setup information on the side of the printer box up the printer. Follow the set of instructions for local, or on the Lexmark Web site at www.lexmark.com. network, or wireless, depending on what you need.
Description Where to find The Help gives you instructions for using the software. While in any Lexmark software program, click Help, Tips Help, or Help Help Topics.

Customer support

Description Telephone support Where to find (North America) Call us at Where to find (rest of world) Telephone numbers and support hours vary by country or region.

US: 1-800-332-4120

MondayFriday (8:00 AM11:00 PM ET) Visit our Web site at www.lexmark.com. Select a country or region, and then select Saturday (Noon6:00 PM ET) the Customer Support link. Canada: 1-800-539-6275 Note: For additional information about MondayFriday (8:00 AM11:00 PM ET) contacting Lexmark, see the printed Saturday (Noon6:00 PM ET) warranty that came with your printer.

Mexico: 001-888-377-0063

13 Replace the system board cover and close the system board door.
Installing a printer hard disk
The optional printer hard disk can be installed with or without a Lexmark Internal Solutions Port (ISP). Note: This task requires a flathead screwdriver. CAUTIONSHOCK HAZARD: If you are accessing the system board or installing optional hardware or memory devices sometime after setting up the printer, then turn the printer off, and unplug the power cord from the wall outlet before continuing. If you have any other devices attached to the printer, then turn them off as well, and unplug any cables going into the printer. WarningPotential Damage: System board electronic components are easily damaged by static electricity. Touch something metal on the printer before touching any system board electronic components or connectors.
2 Unpack the printer hard disk.
Note: If an optional ISP is currently installed, then the printer hard disk must be installed onto the ISP. To install a printer hard disk onto the ISP:
a Using a flathead screwdriver to loosen the screws, remove the thumbscrews that attach the printer hard disk
mounting bracket to the printer hard disk, and then remove the bracket.
b Align the standoffs of the printer hard disk with the holes in the ISP, and then press downward on the printer
hard disk until the standoffs have seated into place.
c Insert the plug of the printer hard disk interface cable into the receptacle of the ISP.
To install a printer hard disk directly onto the system board:
a Align the standoffs of the printer hard disk with the holes in the system board, and then press downward on
the printer hard disk until the standoffs have seated into place.
b Attach the two provided screws to secure the printer hard disk mounting bracket.
c Insert the plug of the printer hard disk interface cable into the receptacle of the system board.
4 Replace the system board cover and close the system board door.
Installing hardware options

Order of installation

CAUTIONTIPPING HAZARD: Floor-mounted configurations require additional furniture for stability. You must use either a printer stand or printer base if you are using a high-capacity input tray, a duplex unit and an input option, or more than one input option. If you purchased a multifunction printer (MFP) that scans, copies, and faxes, you may need additional furniture. For more information, see www.lexmark.com/multifunctionprinters. Install the printer and any options you have purchased in the following order: CAUTIONSHOCK HAZARD: If you are accessing the system board or installing optional hardware or memory devices sometime after setting up the printer, then turn the printer off, and unplug the power cord from the wall outlet before continuing. If you have any other devices attached to the printer, then turn them off as well, and unplug any cables going into the printer.

You have completed the initial setup of the printer. The printer is connected to your network with the appropriate type of cable.
1 Insert the Software and Documentation CD.
Wait for the Welcome screen to appear. If the CD does not launch after a minute, then do the following:
a Click , or click Start and then click Run. b In the Start Search or Run box, type D:\setup.exe, where D is the letter of your CD or DVD drive. 2 Click Install Printer and Software. 3 Click Agree to agree to the License Agreement. 4 Select Suggested, and then click Next.
Note: To configure the printer using a static IP address, using IPv6, or to configure printers using scripts, select Custom and follow the on-screen instructions.
5 Select Wired Network Attach, and then click Next. 6 Select the printer manufacturer from the list. 7 Select the printer model from the list, and then click Next. 8 Select the printer from the list of printers discovered on the network, and then click Finish.
Note: If your configured printer does not appear in the list of discovered printers, click Add Port and follow the on-screen instructions.
9 Follow the on-screen instructions to complete the installation.
1 Allow the network DHCP server to assign an IP address to the printer. 2 Print the network setup page from the printer. For information on printing a network setup page, see Printing
a network setup page on page 38.
3 Locate the printer IP address in the TCP/IP section of the network setup page. You will need the IP address if you
are configuring access for computers on a different subnet than the printer.
4 Install the drivers and add the printer. a Install a PPD file on the computer: 1 Insert the Software and Documentation CD in the CD or DVD drive. 2 Double-click the installer package for the printer. 3 From the Welcome screen, click Continue. 4 Click Continue again after viewing the Readme file. 5 Click Continue after viewing the license agreement, and then click Agree to accept the terms of the 8 9
agreement. Select a Destination, and then click Continue. From the Easy Install screen, click Install. Type the user password, and then click OK. All the necessary software is installed on the computer. Click Restart when installation is complete.
b Add the printer: For IP printing:
In Mac OS X version 10.5 or later
From the Apple menu, choose System Preferences. Click Print & Fax. Click +. Click IP. Type in the IP address of your printer in the Address field. Click Add.

If the CD does not launch automatically, then do the following: 1 Click , or click Start and then click Run. 2 In the Start Search or Run box, type D:\setup.exe, where D is the letter of your CD or DVD drive.

b c d e

Click Install Printer and Software. Click Agree to accept the Printer Software License Agreement. Click Custom. Make sure Select Components is selected, and then click Next. Additional printer setup

f g h i j

Make sure Local is selected, and then click Next. Select the manufacturer of the printer from the menu. Select the printer model from the menu, and then click Add Printer. Click the + beside the printer model under Select Components. Make sure the correct port is available under Select Components. This is the port where the serial cable attaches to the computer. If the correct port is not available, select the port under the Select Port menu, and then click Add Port. the port.
k Make any configuration changes necessary in the Add a New Port window. Click Add Port to finish adding l Make sure the box next to the selected printer model is checked. m Select any other optional software you want to install, and then click Next. n Click Finish to complete the printer software installation. 3 Set the COM port parameters:
After the printer driver is installed, you must set the serial parameters in the communications (COM) port assigned to the printer driver. The serial parameters in the COM port must match the serial parameters you set in the printer.
a Open the Device Manager. 1 Click , or click Start and then click Run. 2 In the Start Search or Run box, type devmgmt.msc. 3 Press Enter, or click OK.
The Device Manager opens.
Click + to expand the list of available ports. Select the communications port where you attached the serial cable to your computer (example: COM1). Click Properties. On the Port Settings tab, set the serial parameters to the same serial parameters in the printer. Look for the printer settings under the serial heading on the Menu Settings page you printed earlier.

also contaminate the printer and the cartridge with adhesive, and could void the printer and cartridge warranties.
Do not use labels with exposed adhesive. Do not print within 1 mm (0.04 in.) of the edge of the label, of the perforations, or between die-cuts of the label. Be sure adhesive backing does not reach to the sheet edge. Zone coating of the adhesive at least 1 mm (0.04 in.)
away from edges is recommended. Adhesive material contaminates the printer and could void the warranty. and use a non-oozing adhesive.
If zone coating of the adhesive is not possible, remove a 1.6-mm (0.06-in.) strip on the leading and driver edge, Portrait orientation works best, especially when printing bar codes.

Tips on using card stock

Card stock is heavy, single-ply specialty media. Many of its variable characteristics, such as moisture content, thickness, and texture, can significantly impact print quality. Print samples on the card stock being considered for use before buying large quantities. When printing on card stock:
Feed card stock from a 250-sheet tray, a 550-sheet tray, or the multipurpose feeder. Make sure the Paper Type is Card Stock. Select the appropriate Paper Texture setting. Be aware that preprinting, perforation, and creasing may significantly affect the print quality and cause jams or other paper handling problems. without releasing hazardous emissions.
Check with the manufacturer or vendor to ensure the card stock can withstand temperatures up to 230C (446F) Do not use preprinted card stock manufactured with chemicals that may contaminate the printer. Preprinting
introduces semi-liquid and volatile components into the printer.
Use grain short card stock when possible.
Printing confidential and other held jobs
Holding jobs in the printer
When sending a job to the printer, you can specify that you want the printer to hold the job in memory until you start the job from the printer control panel. All print jobs that can be initiated by the user at the printer are called held jobs. Note: Confidential, Verify, Reserve, and Repeat print jobs may be deleted if the printer requires extra memory to process additional held jobs.
Job type Confidential Description When you send a Confidential print job to the printer, you must create a PIN from the computer. The PIN must be four digits using the numbers 09. The job is held in printer memory until you enter the PIN from the printer control panel and choose to print or delete the job. When you send a Verify print job, the printer prints one copy and holds the remaining copies in printer memory. Verify lets you examine the first copy to see if it is satisfactory before printing the remaining copies. Once all copies are printed, the job is automatically deleted from printer memory. When you send a Reserve print job, the printer does not print the job immediately. It stores the job in memory so you can print the job later. The job is held in memory until you delete it from the Held Jobs menu. When you send a Repeat print job, the printer prints all requested copies of the job and stores the job in memory so you can print additional copies later. You can print additional copies as long as the job remains stored in memory.

1 Clear the jam from the stapler output bin.

2 Press

282 paper jam
To prevent paper jams, the stapler motor does not run when the stapler door is open.
1 Close the stapler door until it clicks into place.

283 staple jam

1 Press the latch to open the stapler door.
2 Pull the latch of the staple cartridge holder down, and then pull the holder out of the printer.
3 Use the metal tab to lift the staple guard, and then remove any loose staples.
4 Press down on the staple guard until it snaps into place.
5 Push the cartridge holder firmly back into the stapler unit until the cartridge holder clicks into place. 6 Close the stapler door. 7 Press
Understanding printer menus

Menus list

A number of menus are available to make it easy for you to change printer settings:
Paper Menu Default Source Paper Size/Type Configure MP Envelope Enhance Substitute Size Paper Texture Paper Weight Paper Loading Custom Types Universal Setup Bin Setup
Reports Menu Settings Page Device Statistics Network Setup Page1 Profiles List NetWare Setup Page Print Fonts Print Directory Asset Report
Network/Ports Active NIC Standard Network2 Standard USB Parallel <x> Serial <x> SMTP Setup
Depending on the printer setup, this menu item appears as Network Setup Page or Network <x> Setup Page. Depending on the printer setup, this menu item appears as Standard Network or Network <x>. Settings General Settings Setup Menu Finishing Menu Quality Menu Utilities Menu XPS Menu PDF Menu PostScript Menu PCL Emul Menu HTML Menu Image Menu Flash Drive Menu Help Print All Print Quality Printing Guide Media Guide Print Defects Menu Map Information Guide Connection Guide Moving Guide Supplies Guide
Security Miscellaneous Security Settings Confidential Print Disk Wiping Security Audit Log Set Date/Time

Paper menu

Default Source menu
Menu item Default Source Tray <x> MP Feeder Envelope Feeder Manual Paper Manual Env Description Sets a default paper source for all print jobs Notes:
Tray 1 (standard tray) is the factory default setting. Only an installed paper source will appear as a menu setting. A paper source selected by a print job will override the Default Source

Printer busy, Continue, Quit
Press to read the information from the flash drive. Select Quit to cancel the information retrieval process.
Printing from USB drive DO NOT REMOVE
WarningPotential Damage: Do not turn the printer off or remove the flash drive while this message is displayed. Wait for the message to clear.
Programming disk DO NOT POWER OFF
Wait for the message to clear. WarningPotential Damage: Do not turn the printer power off while Programming disk appears on the display.
Programming flash DO NOT POWER OFF
Wait for the message to clear. WarningPotential Damage: Do not turn the printer power off while Programming flash appears on the display.
Reading USB drive DO NOT REMOVE
The printer is ready to receive print jobs.

Reattach bin <x>

Turn the printer off. Unplug the power cord from the wall outlet. Remove the specified bin. Reattach the bin. Connect the power cord to a properly grounded outlet. Restart the printer. Turn the printer off. Unplug the power cord from the wall outlet. Remove the specified bin. Contact Customer Support. to clear the message and print without using the specified bin.
Reattach bin <x> <y>
Turn the printer off. Unplug the power cord from the wall outlet. Remove the specified bins. Reattach the bins. Connect the power cord to a properly grounded outlet. Restart the printer. Turn the printer off. Unplug the power cord from the wall outlet. Remove the specified bins. Contact Customer Support. Understanding printer messages
to clear the message and print without using the specified bins.

Reattach envelope feeder

Turn the printer off. Unplug the power cord from the wall outlet. Remove the envelope feeder. Reattach the envelope feeder. Connect the power cord to a properly grounded outlet. Restart the printer. Turn the printer off. Unplug the power cord from the wall outlet. Remove the envelope feeder. Contact Customer Support. to clear the message and print without using the envelope feeder.
Remote Management Active DO NOT POWER OFF

Ordering print cartridges
When 88 Cartridge low appears or when the print becomes faded:
1 Remove the print cartridge. 2 Firmly shake the cartridge side-to-side and front-to-back several times to redistribute toner.
3 Reinsert the cartridge and continue printing.
Note: Repeat this procedure multiple times until the print remains faded, and then replace the cartridge.
Recommended print cartridges
Part name For the US and Canada Print Cartridge High Yield Print Cartridge Extra High Yield Print Cartridge* High Yield Print Cartridge for Label Applications Extra High Yield Print Cartridge for Label Applications* Print Cartridge High Yield Print Cartridge Extra High Yield Print Cartridge* High Yield Print Cartridge for Label Applications Extra High Yield Print Cartridge for Label Applications* For the Asia Pacific Region Print Cartridge High Yield Print Cartridge Extra High Yield Print Cartridge* High Yield Print Cartridge for Label Applications Extra High Yield Print Cartridge for Label Applications* For Latin America Print Cartridge High Yield Print Cartridge Extra High Yield Print Cartridge* High Yield Print Cartridge for Label Applications Extra High Yield Print Cartridge for Label Applications* * Available for the T654 models. T650A11L T650H11L T654X11L T650H04L T654X04L T650A21L T650H21L T654X21L Not applicable Not applicable T650A11P T650H11P T654X11P T650H04P T654X04P T650A21P T650H21P T654X21P Not applicable Not applicable T650A11A T650H11A T654X11A T650H04A T654X04A T650A21A T650H21A T654X21A Not applicable Not applicable Lexmark Return Program Cartridge Regular cartridge
For Europe, the Middle East, and Africa T650A11E T650H11E T654X11E T650H04E T654X04E T650A21E T650H21E T654X21E Not applicable Not applicable
Ordering a maintenance kit
When 80 Routine maintenance needed appears, order a maintenance kit. The maintenance kit contains all the items necessary to replace the pick rollers, the charge roll, the transfer roller, and the fuser. Maintaining the printer

2 Click Reports, and then click the type of report you want to view.

Adjusting Power Saver

Available settings range from 1240 minutes. The factory default is 30 minutes. To increase or decrease the number of minutes before the printer enters Power Saver mode, do one of the following:
2 Click Settings, and then click General Settings. 3 Click Timeouts. 4 In the Power Saver box, increase or decrease the number of minutes you want the printer to wait before it enters

Power Saver mode.

5 Click Submit.
Using the printer control panel
1 Make sure the printer is on and Ready appears. 2 Press
. Settings appears, and then press.
3 Press the arrow buttons until 4 Press the arrow buttons until 5 Press the arrow buttons until 6 Press the arrow buttons until

mode, and then press.

General Settings appears, and then press Timeouts appears, and then press.
Power Saver appears, and then press
7 Press the arrow buttons to increase or decrease the number of minutes before the printer enters Power Saver
Restoring the factory default settings
If you want to retain a list of the current menu settings for reference, then print a menu settings page before you restore the factory default settings. For more information, see Printing a menu settings page on page 38. WarningPotential Damage: Restoring factory defaults returns most printer settings to the original factory default setting. Exceptions include the display language, custom sizes and messages, and Network/Port menu settings. All downloads stored in RAM are deleted. Downloads stored in flash memory or on a printer hard disk are not affected.
1 From the printer control panel, press 2 Press the arrow buttons until 3 Press the arrow buttons until 4 Press the arrow buttons until 5 Press the arrow buttons until
Settings appears, and then press
General Settings appears, and then press Factory Defaults appears, and then press Restore Now appears, and then press.
Restoring Factory Defaults appears.

Troubleshooting

Solving basic problems
Solving basic printer problems
If there are basic printer problems, or the printer is unresponsive, make sure:
The power cord is plugged into the printer and a properly grounded electrical outlet. The electrical outlet is not turned off by any switch or breaker. The printer is not plugged into any surge protectors, uninterrupted power supplies, or extension cords. Other electronic equipment plugged into the outlet is working. The printer is turned on. Check the printer power switch. The printer cable is securely attached to the printer and the host computer, print server, option, or other network device.

Ghost images

CHECK THE PAPER TYPE SETTING

Gray background

CHECK THE TONER DARKNESS SETTING
Select a lighter Toner Darkness setting:
From the printer control panel, change the setting from the Quality menu. For Windows users, change the setting from Print Properties. For Macintosh users, change the setting from the Print dialog.

Incorrect margins

Paper curl
THE PAPER HAS ABSORBED MOISTURE DUE TO HIGH HUMIDITY

Print irregularities

Avoid textured paper with rough finishes.
When 88 Cartridge low appears or when the print becomes faded, replace the print cartridge.
THE FUSER MAY BE WORN OR DEFECTIVE

Replace the fuser.

Print is too dark
CHECK THE DARKNESS, BRIGHTNESS, AND CONTRAST SETTINGS
The Toner Darkness setting is too dark, the Brightness setting is too dark, or the Contrast setting is too high.
From the printer control panel, change these settings from the Quality menu. For Windows users, change these settings from Print Properties. For Macintosh users, change these settings from the Print dialog and pop-up menus.
THE PRINT CARTRIDGE MAY BE DEFECTIVE
Replace the print cartridge.

Print is too light

The Toner Darkness setting is too light, the Brightness setting is too light, or the Contrast setting is too low.

THE TONER IS LOW

When 88 Cartridge Low appears, order a new print cartridge.

Repeating defects

REPEATING MARKS OCCUR EVENLY DOWN THE PAGE
Replace the charge rolls if the defects occur every 28.3 mm (1.11 in.). Replace the transfer roller if the defects occur every 51.7 mm (2.04 in.). Replace the print cartridge if the defects occur every:
47.8 mm (1.88 in.) 96.8 mm (3.81 in.)
Replace the fuser if the defects occur every:
88.0 mm (3.46 in.) 95.2 mm (3.75 in.)

Skewed print

Make sure you are using paper that meets the printer specifications.
Solid black or white streaks
MAKE SURE THE FILL PATTERN IS CORRECT
If the fill pattern is incorrect, then choose a different fill pattern from your software program or application.

CHECK THE PAPER TYPE

Try a different type of paper. Use only transparencies recommended by the printer manufacturer. Make sure the Paper Type and Paper Texture settings match the paper loaded in the tray or feeder.

MAKE SURE THE TONER IS DISTRIBUTED EVENLY IN THE PRINT CARTRIDGE
Remove the print cartridge and shake it from side to side to redistribute the toner, and then reinstall it.
THE PRINT CARTRIDGE MAY BE DEFECTIVE OR LOW ON TONER
Replace the used print cartridge with a new one.

Solid color pages

MAKE SURE THE PRINT CARTRIDGE IS PROPERLY INSTALLED
Replace the used print cartridge with a new one. If the problem continues, the printer may need to be serviced. For more information, contact Customer Support. Troubleshooting
Streaked horizontal lines
These are the possible solutions. Try one or more of the following:

THE TONER IS SMEARED

Select another tray or feeder to feed the paper for the job:
From the printer control panel, select the Default Source from the Paper Menu. For Windows users, select the paper source from Print Properties. For Macintosh users, select the paper source from the Print dialog and pop-up menus.
THE PAPER PATH MAY NOT BE CLEAR
Check the paper path around the print cartridge. CAUTIONHOT SURFACE: The inside of the printer might be hot. To reduce the risk of injury from a hot component, allow the surface to cool before touching. Clear any paper you see.
THERE IS TONER IN THE PAPER PATH
Contact Customer Support.

Streaked vertical lines

Select another tray or feeder to feed paper for the job:
THE PRINT CARTRIDGE IS DEFECTIVE
Toner fog or background shading appears on the page
THE CHARGE ROLLS MAY BE DEFECTIVE
Replace the charge rolls.
Clean any toner from the paper path. If the problem persists, then contact Customer Support.

Toner rubs off

These are possible solutions. Try one or more of the following: Troubleshooting
CHECK THE PAPER TEXTURE SETTING
From the printer control panel Paper menu, make sure the Paper Texture setting matches the paper loaded in the tray.

Toner specks

Transparency print quality is poor

CHECK THE TRANSPARENCIES

Use only transparencies recommended by the printer manufacturer.
Contacting Customer Support
When you call Customer Support, describe the problem you are experiencing, the message on the display, and the troubleshooting steps you have already taken to find a solution. You need to know your printer model type and serial number. For more information, see the label on the inside top front cover of the printer. The serial number is also listed on the menu settings page. In the U.S. or Canada, call (1-800-539-6275). For other countries/regions, visit the Lexmark Web site at www.lexmark.com.

Extent of limited warranty
Lexmark does not warrant uninterrupted or error-free operation of any product or the durability or longevity of prints produced by any product. Warranty service does not include repair of failures caused by: Modification or unauthorized attachments Accidents, misuse, abuse or use inconsistent with Lexmark users guides, manuals, instructions or guidance Unsuitable physical or operating environment Maintenance by anyone other than Lexmark or a Lexmark authorized servicer Operation of a product beyond the limit of its duty cycle Use of printing media outside of Lexmark specifications Refurbishment, repair, refilling or remanufacture by a third party of products, supplies or parts Products, supplies, parts, materials (such as toners and inks), software, or interfaces not furnished by Lexmark
TO THE EXTENT PERMITTED BY APPLICABLE LAW, NEITHER LEXMARK NOR ITS THIRD PARTY SUPPLIERS OR REMARKETERS MAKE ANY OTHER WARRANTY OR CONDITION OF ANY KIND, WHETHER EXPRESS OR IMPLIED, WITH RESPECT TO THIS PRODUCT, AND SPECIFICALLY DISCLAIM THE IMPLIED WARRANTIES OR CONDITIONS OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, AND SATISFACTORY QUALITY. ANY WARRANTIES THAT MAY NOT BE DISCLAIMED UNDER APPLICABLE LAW ARE LIMITED IN DURATION TO THE WARRANTY PERIOD. NO WARRANTIES, EXPRESS OR IMPLIED, WILL APPLY AFTER THIS PERIOD. ALL INFORMATION, SPECIFICATIONS, PRICES, AND SERVICES ARE SUBJECT TO CHANGE AT ANY TIME WITHOUT NOTICE.

Limitation of liability

Your sole remedy under this limited warranty is set forth in this document. For any claim concerning performance or nonperformance of Lexmark or a Remarketer for this product under this limited warranty, you may recover actual damages up to the limit set forth in the following paragraph. Lexmark's liability for actual damages from any cause whatsoever will be limited to the amount you paid for the product that caused the damages. This limitation of liability will not apply to claims by you for bodily injury or damage to real property or tangible personal property for which Lexmark is legally liable. IN NO EVENT WILL LEXMARK BE LIABLE FOR ANY LOST PROFITS, LOST SAVINGS, INCIDENTAL DAMAGE, OR OTHER ECONOMIC OR CONSEQUENTIAL DAMAGES. This is true even if you advise Lexmark or a Remarketer of the possibility of such damages. Lexmark is not liable for any claim by you based on a third party claim. This limitation of remedies also applies to claims against any Suppliers and Remarketers of Lexmark. Lexmark's and its Suppliers' and Remarketers' limitations of remedies are not cumulative. Such Suppliers and Remarketers are intended beneficiaries of this limitation.

Edition: September 17, 2009
Lexmark T650, T650n, T652dn, T654dn & T656dne Printer 4062-XXX
Table of contents Start diagnostics Safety and notices Trademarks Index
Lexmark and Lexmark with diamond design are trademarks of Lexmark International, Inc., registered in the United States and/or other countries.

4062-XXX

Edition: September 17, 2009 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. Comments may be addressed to Lexmark International, Inc., Department D22X/002-1, 740 West New Circle Road, Lexington, Kentucky 40550, U.S.A or e-mail at ServiceInfoAndTraining@Lexmark.com. Lexmark may use or distribute any of the information you supply in any way it believes appropriate without incurring any obligation to you. 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 users responsibility. Lexmark, Lexmark with diamond design, and MarkNet 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. All other trademarks are the property of their respective owners. 2008 Lexmark International, Inc. All rights reserved. UNITED STATES GOVERNMENT RIGHTS This software and any accompanying documentation provided under this agreement are commercial computer software and documentation developed exclusively at private expense.

P/N 12G9824

Table of contents
Table of contents. iii Notices and safety information. xv
Laser notice. xv Lithium warning. ii-xxi Safety information. xxi

Preface. xxiv

Conventions. xxiv

General information

1-1 1-2 1-2 1-2 1-3 1-3 1-4 1-6 1-6 1-7 1-7 1-8 1-9
Maintenance approach. Options. Available internal options. Media handling options. Printer configurations. Basic model. Fully configured model. Supported paper sizes, types, and weights. Paper sizes supported by the printer. Paper types and weights supported by the printer. Paper types and weights supported by the output bins. Tools required. Acronyms.
Diagnostic information. 2-1
Start. 2-1 Confirm the installation status. 2-2 Power-on Reset sequence. 2-2 Entering Diagnostics mode. 2-2 User attendance messages. 2-3 Error code table 1. 2-14 Service checks. 2-126 Sensor (input) service check. 2-126 Sensor (fuser output) service check. 2-126 Sensor (narrow media) service check. 2-127 Sensor (duplex input) service check. 2-127 Sensor (duplex input) service check (external duplex only). 2-128 Sensor (duplex exit) service check (external duplex only). 2-128 Sensor (pass through) service check. 2-129 Sensor (envelope feeder empty) service check. 2-129 Sensor (input) late jam service check. 2-129 Sensor (input) lingering jam service check. 2-132 Sensor (input) early jam service check. 2-133 Sensor (input) static jam service check. 2-135 Sensor (fuser output) late jam service check. 2-135 Sensor (fuser output) lingering jam service check. 2-137 Sensor (fuser output) static jam service check. 2-138 Sensor (narrow media) late jam service check. 2-139 Sensor (narrow media) static jam service check. 2-140 Sensor (duplex input) late jam service check. 2-141 Sensor (duplex input) lingering jam service check. 2-142 Sensor (duplex input) static jam service check. 2-144 Sensor (pass through) late jam service check. 2-145
Sensor (pass through) lingering jam service check.2-146 Sensor (pass through) static jam service check.2-147 Sensor (stapler pass through) late jam service check.2-148 Sensor (stapler pass through) lingering jam service check.2-149 Sensor (stapler pass through) static jam service check.2-149 Sensor (output pass through) late jam service check.2-150 Sensor (output pass through) lingering jam service check.2-151 Sensor (output pass through) static jam service check.2-152 Sensor (mailbox empty) late jam service check.2-153 Sensor (mailbox empty) lingering jam service check.2-154 Sensor (mailbox empty) static jam service check.2-154 Sensor (toner empty) service check.2-155 NVRAM mismatch failure (950.00 through 950.29) service check.2-155.2-156 Image quality trouble.2-157 Printer Related Troubleshooting.2-157 Image quality symptoms.2-157 Image Quality.2-158 Faint print (Low contrast).2-158 Blank print (no print).2-160 Solid black.2-162 Vertical lines and bands (process direction).2-163 Horizontal white stripes or bands (side to side direction).2-164 Vertical stripes (process direction).2-165 Horizontal stripes (side to side direction).2-166 Partial lack.2-168 Spots.2-169 After image.2-171 Background (fog).2-172 Skew.2-173 Media damage.2-174 No fuse.2-176 Network service check.2-177

Diagnostic aids. 3-1

Understanding the printer control panel (models T650, T652, and T654).3-1 Accessing service menus (models T650, T652, and T654).3-2 Diagnostics mode (models T650, T652, and T654).3-3 Entering Diagnostics mode (models T650, T652, and T654).3-3 Available tests.3-3 Exiting Diagnostics mode (models T650, T652, and T654).3-5 REGISTRATION.3-5 Quick Test.3-6 PRINT TESTS.3-7 Input source tests.3-7 Print quality pages (Prt Quality Pgs).3-7 HARDWARE TESTS.3-8 Panel Test.3-8 Button Test.3-8 DRAM Test.3-8 USB HS Test Mode.3-9 RFID Option Test.3-10 DUPLEX TESTS.3-12 Quick Test (duplex).3-12 Top Margin (duplex).3-13 Sensor Test (duplex).3-13 Motor Test (duplex).3-14 Duplex Feed 1.3-14 Duplex Feed 2.3-14

iv Service Manual

INPUT TRAY TESTS. Feed Tests (input tray). Sensor Test (input tray). OUTPUT BIN TESTS. Feed Tests (output bins). Feed To All Bins. Sensor Test (standard output bin). Sensor Test (Output Expander). Sensor Test (high capacity output stacker). Sensor Tests (5-bin mailbox). Deflector Test. StapleSmart FINISHER TESTS. Staple Test. Feed Tests (finisher). Sensor Test (finisher). BASE SENSOR TEST. PRINTER SETUP. Defaults. Printed Page Count. Perm Page Count (permanent page count). Serial Number. Engine Setting 1 through 16. Model Name. Configuration ID. Edge to Edge. EP SETUP. EP Defaults. Fuser Temperature (Fuser Temp). Fuser Page Count. Warm Up Time. Transfer. Print Contrast. Charge Roll. Gap Adjust. Auto Dark Adj. REPORTS. EVENT LOG. Display Log. Print Log. Clear Log. EXIT DIAGNOSTICS (models T650, T652, and T654). Configuration menu (CONFIG MENU) (models T650, T652, and T654). Entering Configuration Menu (models T650, T652, and T654). Available menus. Maintenance page count (Maint Cnt Value). Maintenance page counter reset (Reset Cnt). Print quality pages (Prt Quality Pgs). Reports. SIZE SENSING. Panel Menus. PPDS Emulation. Demo Mode. Factory Defaults. LES Applications. Energy Conserve. Paper Prompts. Env Prompts. Action for Prompts. Font Sharpening.
3-14 3-15 3-15 3-15 3-15 3-16 3-16 3-17 3-17 3-18 3-18 3-18 3-18 3-18 3-18 3-19 3-19 3-19 3-19 3-20 3-20 3-20 3-20 3-20 3-21 3-21 3-21 3-21 3-21 3-21 3-21 3-22 3-22 3-22 3-22 3-23 3-23 3-23 3-23 3-24 3-24 3-25 3-25 3-25 3-25 3-26 3-26 3-26 3-27 3-27 3-27 3-27 3-28 3-28 3-28 3-28 3-28 3-28 3-28
Wiper Messages.3-28 Clear Custom Status.3-28 Best Speed.3-29 Exit Config Menu (models T650, T652, and T654).3-29 Understanding the printer control panel (model T656).3-29 Accessing service menus (model T656).3-30 Diagnostics Menu (model T656).3-31 Entering Diagnostics Menu (model T656).3-31 Available tests.3-31 Registration (printer).3-33 Quick Test.3-34 PRINT TESTS.3-35 Input source tests.3-35 Printing Quality Pages.3-35 HARDWARE TESTS.3-36 Panel Test.3-36 Button Test.3-36 DRAM Test.3-37 USB HS Test Mode.3-37 DUPLEX TESTS.3-38 Quick Test (duplex).3-38 Top Margin (duplex).3-38 Left Margin (duplex).3-39 Sensor Test (duplex).3-39 Motor Test (duplex).3-39 Duplex Feed 1.3-40 Duplex Feed 2.3-40 INPUT TRAY TESTS.3-40 Feed Tests (input tray).3-40 Sensor Test (input tray).3-41 OUTPUT BIN TESTS.3-41 Feed Tests (output bins).3-41 Sensor Test (standard output bin).3-41 BASE SENSOR TEST.3-42 DEVICE TESTS.3-43 Quick Disk Test.3-43 Disk Test/Clean.3-43 PRINTER SETUP.3-44 Defaults.3-44 Printed Page Count.3-44 Permanent Page Count.3-44 Serial Number.3-44 Engine Settings 1 through 16.3-44 Model Name.3-44 Configuration ID.3-45 Edge to Edge.3-45 EP SETUP.3-45 EP Defaults.3-46 Fuser Temperature (Fuser Temp).3-46 Fuser Page Count.3-46 Warm Up Time.3-46 Transfer.3-46 Print Contrast.3-46 Charge Roll.3-46 Gap Adjust.3-47 Auto Dark Adjust.3-47 REPORTS.3-47 Menu Settings Page.3-47 EVENT LOG.3-47

vi Service Manual

Display Log. Print Log. Clear Log. Configuration menu (CONFIG MENU) (model T656). Entering Configuration Menu (model T656). Available menus. Maintenance Counter Value. Reset Maintenance Counter. Print Quality Pages. Reports. Menu Settings Page. Event Log. SIZE SENSING. Panel Menus. PPDS Emulation. Factory Defaults. Energy Conserve. Paper Prompts. Envelope Prompts. Action for Prompts. Jobs On Disk. Disk Encryption. Wipe Disk. Font Sharpening. Require Standby. LES Applications. Key Repeat Initial Delay. Key Repeat Rate. Wiper Message. Clear Custom Status. USB speed. Exit Configuration Menu (model T656). Printer overview. Basic model. Printer theory. Model T650 with duplex, paper path, rolls, and sensors. Models T652 and T654 paper path rolls and sensors. Functions of main components. Media tray assembly. Rear media guide. Side guide. Wear strips. Media tray assembly. Detection of media size. Pick arm assembly. Switch (media size). Sensor (media empty). Sensor (media low). Multi-purpose feeder (MPF). MPF feed roll. MPF pick solenoid. Sensor (MPF media empty). Supported paper sizes, types, and weights. Paper sizes supported by the printer. Registration. Sensor (input). Aligner assembly. Transfer. Transfer roll assembly.
3-47 3-48 3-48 3-49 3-49 3-49 3-49 3-50 3-51 3-51 3-51 3-51 3-52 3-52 3-52 3-54 3-54 3-55 3-55 3-55 3-55 3-56 3-57 3-57 3-57 3-58 3-58 3-58 3-58 3-58 3-59 3-59 3-60 3-60 3-61 3-61 3-62 3-62 3-62 3-62 3-63 3-63 3-63 3-63 3-64 3-65 3-65 3-65 3-65 3-65 3-65 3-65 3-66 3-66 3-67 3-67 3-67 3-68 3-68
Polygon printhead assembly.3-69 Oscillating printhead assembly.3-71 Fuser.3-72 Fuser components.3-72 Heat roll.3-73 Pressure roll.3-73 Heater lamp.3-73 Thermal cutoff.3-73 Thermistor.3-73 Sensor (fuser output).3-73 Sensor (narrow media).3-73 Fuser unit assembly (type 1 and type 2).3-73 Type 1 fuser unit assembly.3-73 Type 2 fuser unit assembly.3-74 Exit.3-74 Sensor (standard bin full).3-74 Drive.3-75 Main drive motor assembly.3-75 Redrive motor assembly.3-75 Electrical components and controller.3-76 Switch (printer front door interlock).3-76 Main cooling fan.3-76 Print cartridge cooling fan.3-76 Duplex cooling fan.3-76 LVPS card assembly.3-76 HVPS card assembly.3-76 System card assembly.3-77 Control.3-77 Printhead control.3-77 Rotation of printhead motor.3-77 Determination of printhead ready.3-77 Printhead reference value.3-77 Fuser control.3-77 Fuser control method.3-77 Fuser lamp on/off control.3-77 Fuser warm-up.3-78 Xerographic and print cartridge components.3-78 Charge.3-79 Exposure.3-79 Development.3-80 Transfer.3-81 Cleaning.3-82 Auto density sensing.3-83 High Capacity Input Tray (HCIT) tray assembly.3-84 250-sheet/550-sheet tray assembly.3-85 Media size sensing.3-85 Media level sensing.3-86 Pick arm assembly.3-86 Switch (media size).3-87 Sensor (media empty).3-87 Sensor (media low).3-87 Sensor (pass-thru).3-87 Media transport path.3-89 Model T650 paper path, rolls, and sensors.3-89 Models T652 and T654 paper path, rolls, and sensors.3-90 Functions of main components.3-90 Media tray assembly.3-90 Rear media guide.3-90 Side guide.3-90

viii Service Manual

Wear strips. 3-91 Media tray assembly. 3-91 Detection of media size. 3-91 Pick arm assembly. 3-91 Switch (media size). 3-91 Sensor (media empty). 3-91 Sensor (media low). 3-92 Duplex. 3-93 Layout of media transport path. 3-93 Model T650 duplex paper path. 3-93 Models T652 and T654 duplex paper path. 3-94 Functions of main components. 3-94 Sensor (duplex input). 3-94 Duplex drive motor assembly. 3-95 Understanding jam numbers and locations. 3-and 201 paper jams. 3-and 203 paper jams. 3-paper jam. 3-98 Rear paper jams. 3-98 Front paper jams. 3-99 231-239 paper jams (optional external duplex unit). 3-100 Rear paper jams. 3-100 Front paper jams. 3-paper jams. 3-paper jam. 3-paper jam. 3-paper jams. 3-paper jam. 3-paper jam. 3-paper jam. 3-staple jam. 3-106 Security Reset Jumper. 3-108 Security Reset Jumper. 3-108

Repair Information. 4-1

Handling ESD-sensitive parts. 4-1 Adjustments. 4-2 Polygon and Oscillating printhead mechanical registration adjustment. 4-2 Oscillating printhead assembly electronic adjustment. 4-3 Alignment assembly adjustment. 4-4 Fuser solenoid adjustment. 4-6 Gap adjustment. 4-6 Removals. 4-7 Replacement note: To replace a removed part, reverse the order of removal unless noted otherwise. 4-7 Access door removal (T650, T652, T654). 4-8 Alignment assembly removal (T650, T652, T654). 4-8 Connection access cover, rear removal (T650, T652, T654). 4-11 Connection bezel assembly, rear removal (T650). 4-11 Connection bezel assembly, rear removal (T652, T654). 4-12 Cover assembly, rear lower removal (T650). 4-13 Cover assembly, rear lower (T652, T654). 4-13 Charge roll assembly removal (T650, T652, T654). 4-14 Door assembly, rear removal (T650, T652, T654). 4-15 Duplex guide assembly, rear removal (T652, T654). 4-15 Duplex assembly removal (T652, T654). 4-16 Duplex cooling fan removal (T652, T654). 4-18 Duplex drive motor assembly removal (T652, T654). 4-19 Duplex input sensor assembly removal (T652, T654). 4-20
Duplex guide assembly, front removal (T652, T654).4-21 Fuser access door assembly removal (T650, T652, T654).4-22 Fuser drive release linkage removal (T650, T652, T654).4-23 Fuser unit assembly removal (T650, T652, T654).4-23 Fuser wiper cover assembly removal (T650, T652, T654).4-24 HVPS card assembly removal (T650, T652, T654).4-24 Inner deflector removal (T650, T652, T654).4-25 Laser cover removal (T650, T652, T654).4-27 LCD screen bezel removal (T650, T652, T654).4-28 LVPS card assembly removal (T650).4-29 LVPS card assembly removal (T652, T654).4-31 Main cooling fan removal (T650, T652, T654).4-32 Main drive motor assembly removal (T650, T652, T654).4-34 Media out actuator removal (T650, T652, T654).4-35 Media support removal (T650, T652, T654).4-36 Media turn guide removal (T650, T652, T654).4-36 MPF cam gear removal (T650, T652, T654).4-37 MPF lift plate assembly removal (T650, T652, T654).4-37 MPF media out actuator removal (T650, T652, T654).4-38 MPF pick roll assembly removal (T650, T652, T654).4-38 MPF pick solenoid assembly removal (T650, T652, T654).4-39 MPF tray door assembly removal (T650, T652, T654).4-41 Operator panel latch assembly removal (T650, T652, T654).4-43 Operator panel door assembly removal (T650, T652, T654).4-44 Operator panel hinge assembly, left removal (T650, T652, T654).4-45 Operator panel hinge assembly, right removal (T650, T652, T654).4-47 Operator panel door assembly removal (models X651, X652, X654, and X656).4-49 Operator panel cover latch assembly removal (models X651, X652, X654, and X656).4-52 Option drive shaft removal (T650, T652, T654).4-52 Output cover assembly removal (T650, T652, T654).4-54 Pick arm assembly removal (T650, T652, T654).4-54 Pick roll assembly removal (T650, T652, T654).4-57 Print cartridge cooling fan removal (T650, T652, T654).4-57 Print cartridge clamp assembly removal (T650, T652, T654).4-58 Print cartridge ID connector assembly removal (T650, T652, T654).4-59 Printhead assembly removal (T650).4-60 Printhead assembly removal (T652, T654).4-61 Redrive assembly removal (T650, T652, T654).4-62 Redrive motor assembly removal (T652, T654).4-63 Side cover, left removal (T650).4-65 Side cover, left removal (T652 and T654).4-66 Side cover, right removal (T650).4-67 Side cover, right removal (T652, T654).4-68 Sensor (duplex input) removal (T652, T654).4-68 Sensor (media level) removal (T650, T652, T654).4-70 Sensor (media out) removal (T650, T652, T654).4-70 Sensor (toner empty) removal (T650, T652, T654).4-71 Sensor (input) removal (T650, T652, T654).4-71 Sensor shield assembly removal (T650, T652, T654).4-72 Sensor (standard bin exit) removal (T650, T652, T654).4-73 Sensor (toner density) removal (T650, T652, T654).4-73 Standard bin actuator assembly removal (T650, T652, T654).4-73 Switch (media size) assembly removal (T650, T652, T654).4-74 System card assembly removal (T650, T652, T654, T656).4-76 Transfer roll assembly removal (T650, T652, T654).4-78 Transfer roll bracket assembly, left removal (T650, T652, T654).4-79 Transfer roll bracket assembly, right removal (T650, T652, T654).4-80 Transfer deflector removal (T650, T652, T654).4-80 Tray roller catch assembly removal (T650, T652, T654).4-81

x Service Manual

Option removals. 4-83 5-bin mailbox rear door assembly removal. 4-84 5-bin mailbox left outer cover removal. 4-85 5-bin mailbox left inner cover removal. 4-85 5-bin mailbox right outer cover removal. 4-86 5-bin mailbox right inner cover removal. 4-87 5-bin mailbox top cover removal. 4-88 5-bin mailbox media bin full actuator removal. 4-89 5-bin mailbox sensor (pass through) removal. 4-90 5-bin mailbox sensor (media bin empty) removal. 4-91 5-bin mailbox controller card assembly removal. 4-92 5-bin mailbox static brush mylar assembly removal. 4-93 5-bin mailbox media bin fifth deflector removal. 4-94 5-bin mailbox media bin first through fourth deflector removal. 4-95 5-bin mailbox media bin extension assembly removal. 4-96 5-bin mailbox deflector gate solenoid removal. 4-96 5-bin mailbox transport solenoid removal. 4-98 5-bin mailbox sensor (deflector gate HP) removal. 4-99 250-sheet option tray assembly. 4-101 250-sheet media tray assembly removal. 4-101 250-sheet pick arm bracket assembly removal. 4-102 250-sheet media out actuator removal. 4-104 250-sheet frame assembly removal. 4-104 250-sheet controller card assembly removal. 4-106 550-sheet option tray assembly. 4-107 550-sheet media tray assembly removal. 4-107 550-sheet pick arm bracket assembly removal. 4-108 550-sheet bellcrank recoil spring removal. 4-109 550-sheet frame assembly removal. 4-109 550-sheet controller card assembly removal. 4-111 550-sheet option drive shaft with spring removal. 4-113 Anti-tip latch assembly removal. 4-113 High capacity input tray (HCIT). 4-114 High capacity input tray (HCIT) media tray assembly removal. 4-115 High capacity input tray (HCIT) tray cover, front removal. 4-116 High capacity input tray (HCIT) cover, rear removal. 4-118 High capacity input tray (HCIT) cover, right removal. 4-120 High capacity input tray (HCIT) cover, left removal. 4-122 High capacity input tray (HCIT) anti-tip latch assembly removal. 4-123 High capacity input tray (HCIT) drawer slide assembly removal. 4-124 High capacity input tray (HCIT) tray lift drive motor assembly removal. 4-125 High capacity input tray (HCIT) controller card assembly removal. 4-126 High capacity input tray (HCIT) media size actuator assembly removal. 4-127 High capacity input tray (HCIT) pick arm bracket assembly removal. 4-130 High capacity input tray (HCIT) tray closed latch with spring removal. 4-132 High capacity stacker rear door assembly removal. 4-132 High capacity stacker right cover removal. 4-134 High capacity stacker left cover removal. 4-135 High capacity stacker media output bin assembly removal. 4-136 High capacity stacker controller card cover panel removal. 4-137 High capacity stacker switch (media bin HP) removal. 4-138 High capacity stacker sensor (media bin full) assembly removal. 4-139 High capacity stacker sensor (media bin full) bracket assembly removal. 4-139 High capacity stacker controller card assembly (upper and lower) removal. 4-140 High capacity stacker right frame removal. 4-141 High capacity stacker left frame removal. 4-142 High capacity stacker upper deflector gate removal. 4-143 High capacity stacker sensor (pass through) removal. 4-144 High capacity stacker left mounting bracket removal. 4-146

High capacity stacker sensor (deflector gate HP) removal.4-147 Installing / Removing the RFID UHF option.4-148 Lower interface cable assembly removal.4-156 Media size actuator removal.4-157 Media tray catch spring removal.4-158 Media out actuator removal (models T652 and T654).4-158 Media size actuator removal.4-159 Media tray catch spring removal.4-159 Media tray roller catch assembly removal.4-159 Output expander rear door assembly removal.4-161 Output expander left outer cover removal.4-161 Output expander left inner cover removal.4-162 Output expander right outer cover removal.4-162 Output expander right inner cover removal.4-163 Output expander media bin latch (left and right) removal.4-163 Output expander media output bin assembly removal.4-164 Output expander media bin full actuator removal.4-164 Output expander sensors (media bin full) assembly removal.4-165 Output expander sensor (media bin full) bracket assembly removal.4-166 Output expander controller card cover panel removal.4-166 Output expander controller card removal.4-168 Output expander sensor (pass through) removal.4-169 Output expander deflector gate removal.4-170 Output expander sensor (deflector gate HP) removal.4-171 SFP stapler assembly rear door assembly removal.4-172 SFP stapler assembly right cover removal.4-172 SFP stapler assembly left cover removal.4-173 SFP stapler assembly top cover removal.4-174 SFP stapler assembly handle cover removal.4-175 SFP stapler assembly LED sensor cover removal.4-176 SFP stapler assembly sensor (finisher bin media present) removal.4-177 SFP stapler assembly standard output bin LED and LED clear lens removal.4-178 SFP stapler assembly tamper drive belt removal.4-179 SFP stapler assembly tamper drive motor assembly removal.4-180 SFP stapler assembly media stack flap and media stack flap actuator removal.4-181 SFP stapler assembly stapler unit assembly removal.4-182 SFP stapler assembly paddle drive motor assembly removal.4-183 SFP stapler assembly sensor (media stack) removal.4-184 SFP stapler assembly sensor (paddle HP) removal.4-185 SFP stapler assembly sensor (stapler access door interlock) removal.4-186 SFP stapler assembly sensor (tamper HP left and right) removal.4-187 SFP stapler assembly sensor (bin full send) removal.4-188 SFP stapler assembly sensor (bin full receive) removal.4-189 SFP stapler assembly sensor (media in stapler) removal.4-189 SFP stapler assembly sensor (deflector HP) removal.4-190 Stapler/stacker controller card assembly removal.4-192 Sensor (HCIT tray raised HP) with cable assembly removal.4-192 Sensor (HCIT pass through) with cable removal.4-195 Sensor (pass through) with cable removal.4-196 Sensor (pass through) with cable removal.4-196 Tray roller catch assembly removal.4-196 Tray roller catch assembly removal.4-197 Upper interface cable assembly removal.4-197
Connector locations and connections. 5-1

Connections.5-1

Preventive maintenance. 6-1
Safety inspection guide.6-1

xii Service Manual

Lubrication specifications. Individual maintenance part expected life. Scheduled maintenance. Maintenance kit.

6-1 6-1 6-2 6-2

Parts catalog
How to use this parts catalog. 7-1 Assembly 1: Covers. 7-2 Assembly 2: T650, T652, and T654 Operator panel. 7-4 Assembly 3: T656dne Operator panel, MPF and smart card. 7-6 Assembly 4: Drive motor assemblies and duplex. 7-8 Assembly 5: Media path and ducts. 7-10 Assembly 6: Printhead, charge, and transfer. 7-12 Assembly 7: Pick arm assembly, trays, and MPF. 7-14 Assembly 8: LVPS, fuser and electrical cables 1. 7-16 Assembly 9: HVPS, system card, and electrical cables 2. 7-18 Assembly 10: 250 Sheet option tray assembly. 7-20 Assembly 11: 550 Sheet option tray assembly. 7-22 Assembly 12: HCIT Sheet option tray assembly. 7-24 Assembly 13: SFP stapler assembly #1. 7-26 Assembly 14: SFP stapler assembly #2. 7-28 Assembly 15: SFP stapler assembly #3. 7-30 Assembly 16: SFP stapler assembly #4. 7-32 Assembly 17: 5-bin mailbox #1. 7-34 Assembly 18: 5-bin mailbox #2io. 7-36 Assembly 19: High capacity stacker. 7-38 Assembly 20: Output expander. 7-40 Assembly 21: Envelope feeder and external duplex. 7-42 Assembly 22: RFID UHF Option assembly. 7-44 Assembly 23: Miscellaneous. 7-45 Assembly 24: Power cords. 7-47 Assembly 25: Universal trays and accessories. 7-48
Index. I-1 Part number index. I-5