Lexmark T652 -- Bin Full Sensor

A T652n came in the shop with its bin full sensor flag missing. In configuration mode and diagnostics mode, you can 'continue' past the bin full error message to view page counts and the event log, and you can even print a test page in diagnostics mode. Aside from that, the machine is rendered inoperative until the sensor is either replaced or disabled.

Disabling the Sensor

Unplugging the sensor disables it. The message, "Remove paper from standard output bin" will go away and the machine can be used. The sensor's connector on the System PCA can be reached by way of the DIMM slot access panel under the left side cover. Proceed as follows:

1) Access Door
- Open it.

2) Access Panel
- Loosen off two M3x6mm slotted hex head screws (5.5mm A/F).
- Slide the panel forward to free it. It may take a bit of persuasion to get it to move.

3) Sensor Cable Connector
- It's at the extreme upper rear corner of the System PCA.

Replacing the Sensor

The complete sensor assembly is P/N 40X4372. The optical sensor portion only is P/N 40X4369. (That's unlikely ever to fail.) The flag can't be had on its own, you have to get the complete sensor.

The sensor is well tucked away under the top cover. There's no getting at it without removing that cover. Proceed as follows:

1) Cartridge

2) Tray 1

3) Redrive Cap

4) Back Door
- Disengage the support strap from its 'inverted T' slot and pull the door off its hinge pins.

5) Lower Rear Cover w/Fuser Access Door
- Two M3x10mm washerhead threading screws.
- Open the lower door.
- Two M3x6mm black washerhead screws.
- Open the fuser access door -- two claws.
- Tip the cover rearward and lift it off of two hook-points at the bottom.

6)Redrive Assembly
- Two M3x10mm washerhead threading screws.
- Two outward-hooking claws, left and right side, at about the middle.

7) Connection Access Cover
- Open it fully and its hinges can be popped free rearward.

8) Left Side Cover
- Two M3x8mm black washerhead threading screws in the handgrip wells.
- Two M3x10mm washerhead threading screws in deep wells in the side of the toner cartridge cavity.
- There are six claws, and one of them can be quite tenacious. First, pry at the angled upper front lip to free the upper two claws. The troublesome claw is located roughly 3" from the front and 3" from the bottom. You may have to reach in with a long narrow-bladed screwdriver to pry it loose.
- With all the claws freed, the cover comes away easily from its hinges.

9) Right Side Cover
- One M3x10mm washerhead threading screw at the rear.
- Two M3x8mm black washerhead threading screws in the handgrip wells.
- Two M3x10mm washerhead threading screws in shallow wells in the side of the toner cartridge cavity.
- This cover has an array of claws similar to the left side side cover's, but it comes off more easily.

10) Fuser Cleaning Wand Cover w/Wand

11) Top Cover
- One M4x10mm pan head threading screw at the right rear.
- Four M3x10mm washerhead threading screws.
- The front edge has to be forced up past the rear edge of the upper front door. NOTE: It's a bit difficult to get this cover levered back into place at the front, but it is doable without damaging anything.

12) Sensor
- One claw.
- One cable connection at the sensor
- NOTE: A new sensor comes with a cable. Should you choose to install the sensor with its new cable, you'll have to remove the System PCA's cover..

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