Lexmark T64X -- Routine Teardown/Overhaul Checklist

This document is a condensation of a procedure. It can serve as a checklist once one is familiar with all the information in the procedure.

PRELIMINARIES:

1) Auto Size Sensing; Tray Bias Roller

2) Maintenance Count

3) Page Count

4) Event Log

ORDER OF WORK:

1) Toner Cartridge

2) Paper Tray (Tray 1)

3) Redrive Cap

4) Fuser Cleaning Wand Cover

5) Fuser Cleaning Wand

6) Paper Support

7) Back Door

8) Redrive Assembly

9) Left Side Cover

10) Right Side Cover

11) MP Feeder Door/Platform

12) Fuser

13) Power Supply

14 Control Panel Cover and Window

15) Top Cover

16) System PCA Enclosure Cover

17) PTO Cover

18) Upper Deflector

19) MP Feeder Pick Roll

20) MP Feeder Lower Deflector/Elevator Flap Assembly

21) Pick Rolls

22) Inner Deflector

23) Transfer Roller

24) Charge Roller Assembly

25) Post-Transfer Paper Deck

26) Blow out Chassis. Blow out four optical sensors.

27) Printhead

28) Paper Feed Alignment Gearing and Drum Drive Gear -- inspect and clean gear teeth A/R.

29) MP Feeder Pickup Clutch -- lubricate sparingly with WD-40.

30) PTO Vertical Shaft -- pack grease around its two bearings.

31) Transfer Roller Bearings

32) Reassemble the machine back through item '13)', the power supply. Install the MP Feeder Door/Platform, the left and right side covers and the paper support.

33) Wipe the paper tray's slide ledges with WD-40. Fill it with paper and install it in the printer.

34) Install the cartridge. Set the machine aside.

35) Overhaul the fuser per the procedure.

36) Complete the reassembly of the machine.
- Fuser.
- Redrive Assembly.
- Back Door.
- Fuser Cleaning Wand.
- Fuser Cleaning Wand Cover.
- Redrive Cap.

37) Test operability.

38) Clear the error log.

39) Clear the maintenance count.

40) Remove paper from tray 1.

41) Remove the cartridge if it doesn't belong to the machine.

42) Install a bubble-pack restraint under the charge roller.

43) Tape the front of the machine shut.

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FEEDBACK

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Lexmark T65X -- Right Side Charge Rollers Arm

A T652 came in the shop with a damaged right side charge rollers arm. Here's a view of it out of the machine.

There's a bit of it missing by the electrical contact that connects to the bronze pin at the right side end of the charge rollers assembly.

I suspect that rough handling resulted in the left side end of the charge rollers assembly getting dislodged and falling. That would have made the assembly into a gravity-energized lever for snapping the right side arm's retainer.

Here's a view of an intact arm.

The arm is P/N 40X1893. If I can believe Lexmark's service manual illustration, it comes without the spring. I had a written-off T650 to take a good arm from, so I haven't actually seen a new service replacement part to be certain of how it's supplied.

Lexmark's service manual has nothing in it about replacing this part. Proceed as follows; it's not difficult to do.

1) Toner Cartridge

2) Paper Tray (Tray 1)

3) Redrive Cap

4) Fuser Cleaning Wand Cover w/Wand

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

6) Lower Rear Cover w/Fuser Access Door -- T650
- Three M3x10mm black washerhead threading screws.
- Open the fuser access door -- two claws.
- Pull the cover away at your left and slide the cover toward your right. A downward-pointing hook will slide off a lip at the rear of the chassis.
- NOTE: The above-mentioned hook makes this an awkward part to get back in place. You have to exactly re-create the cover's attitude as the hook was coming off to get it back on again.

6) Lower Rear Cover w/Fuser Access Door -- T652
- Two M3x10mm washerhead threading screws.
- Two M3x6mm washerhead screws.
- Open the fuser access door -- two claws.
- Tip the cover rearward and lift it off of two hooks at the bottom.

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

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

9) Left Side Cover
- Two M3x8mm black washerhead screws in the handgrip wells.
- Two M3x10mm washerhead screws in deep wells in the side of the toner cartridge cavity.
- T650: Tug at the front lip and two upper claws and one lower claw will pop free. The cover's rear hinges come away easily.
- T652: Similar, but 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.

10) Right Side Cover
- One M3x10mm washerhead screw at the rear.
- Two M3x8mm black washerhead screws in the handgrip wells.
- Two M3x10mm washerhead screws in shallow wells in the side of the toner cartridge cavity.
- T650: Tug at the front lip and two upper claws and one lower claw will pop free.
- T652: Similar, but there are six claws arrayed as on the left side cover.

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) One Ty-Wrap at Frontward Red Wire

13) Black Charge Wire Spade Terminal at HVPS (High Voltage Power Supply)
- Disconnect the terminal and extract the wire from its restraint at the side.

14) Right Side Charge Rollers Pressure Spring
- Raise the upper front door.
- Unhook the spring at its front end.

15) Hinge/Arm-Link Pin
- One tiny e-clip.

16) Steel Cross-Member at Rear of Chassis (T652 -- not present on T650)
- Three M3x10mm washerhead threading screws.

17) Right Side Charge Rollers Arm
- NOTE: This part is removed by unfastening the upper portion of the right side vertical frame member, and prying the frame member aside until the arm can be slid off its pivot pin. (This is by no means a factory-approved procedure, but it does work and nothing breaks, even though an outrageous amount of prying is needed.)
- Five M4x10mm bright pan head threading screws. They're prominent and easily spotted.
- Pry aside the frame member.
- Raise the arm and slide it off its pivot pin.
- Transfer the spring to the new part.

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FEEDBACK

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LexmarkT63X -- Routine Teardown/Overhaul Checklist

This document is a condensation of a procedure. It can serve as a checklist once one is familiar with all the information in the procedure.

PRELIMINARIES:

1) Auto Size Sensing; Tray Bias Roller

2) Maintenance Count

3) Page Count

4) Error Log

ORDER OF WORK:

1) Toner Cartridge

2) Paper Tray (Tray 1)

3) Redrive Cap

4) Fuser Cleaning Wand Cover

5) Fuser Cleaning Wand

6) Paper Support

7) Back Door

8) Redrive Assembly

9) Left Side Cover

10) Right Side Cover

11) MP Feeder Door/Platform

12) Fuser

13) Power Supply Output Connector Cover

14) Power Supply

15) Control Panel Clear Cover and Overlay

16) Cartridge Access Door w/Latchbar and Spring

17) Top Cover

18) Main Fan Grille

19) System PCA Pan Cover

20) PTO Cover

21) Upper Deflector

22) MP Feeder Pick Roll

23) MP Feeder Lower Deflector/Elevator Flap Assembly

24) Pick Rolls

25) Inner Deflector

26) White Glide

27) Transfer Roller

28) Charge Roller

29) Post-Transfer Paper Deck

30) Blow out Chassis. Blow out four optical sensors.

31) Printhead

32) Paper Feed Alignment Gearing and Drum Drive Gear -- inspect and clean gear teeth A/R.

33) MP Feeder Pickup Clutch -- lubricate sparingly with WD-40.

34) PTO Vertical Shaft -- pack grease around its two bearings.

35) Transfer and Charge Roller Bearings

36) Reassemble the machine back through item '13)', the power supply output connector cover. Install the MP Feeder Door/Platform, the left and right side covers and the paper support.

37) Wipe the paper tray's slide ledges with WD-40. Fill it with paper and install it in the printer.

38) Install the cartridge. Set the machine aside.

39) Overhaul the fuser per the procedure.

40) Complete the reassembly of the machine.
- Fuser.
- Redrive Assembly.
- Back Door.
- Fuser Cleaning Wand.
- Fuser Cleaning Wand Cover.
- Redrive Cap.

41) Test operability.

42) Clear the error log.

43) Clear the maintenance count.

44) Remove paper from tray 1.

45) Remove the cartridge if it doesn't belong to the machine.

46) Install a bubble-pack restraint under the charge roller.

47) Tape the front of the machine shut.

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FEEDBACK

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Lexmark T65X -- Auto Size Sensing

The T65X series has much the same auto size sensing functionality as did the earlier Ts, but the associated hardware has been completely redesigned, and flaky sensing operation is not as easy to test for. Here's a view of the size setting 'fingers' at the left side of a T650's tray. They're set for letter size in the photo.


Lexmark hasn't broken out a service replacement part number for the fingers, or any other tray component, so discarded trays will be your only source of such items. To remove a finger, slide the tray's backstop all the way to the rear and flip the tray upside down. Each finger has a little claw in back that limits how far it can pivot outward. Press on a finger's claw with a small screwdriver blade to free it. Once swung out, a finger can be slipped off its pivot pin. Here's a view of a finger out of a tray, showing the claw I was referring to.


In the chassis of the printer, the lever array, and the PCA with little snap-action pushbutton switches have been done away with; the tray's fingers operate directly on a switch module. Here's a view of the switch module in a T650.

(Not shown in that photo is a rectangular cover that's been removed. The cover has a single claw at its rear end that holds it in place.) The switch module can be removed and replaced directly; no dismantling of the machine is required. The module has two claws on it that hold it in place. Here's a view of a module out of a printer.


Switch Module Replacement

The P/N is 40X4472; Lexmark calls it "switch (media size) assembly". To replace one, proceed as follows:

1) Toner Cartridge

2) Paper Tray (Tray 1)

3) Lay the printer on its left side.

4) Remove the rectangular cover (one claw).

5) Disconnect the cable.

6) Switch Module
- The lower claw is accessible; the upper one isn't. Get the lower claw dislodged, and then it's possible to worry the thing out of place. There's just barely enough clearance, but it does come out and go back in. Don't connect the cable until the module is in place.

- - -

Testing
As in the earlier Ts, the Paper Size item in the Paper Menu reports the size setting being sensed, but it won't report changes made on the fly. You have to exit the Paper Size item and re-enter it to see a changed setting.

- - -

I've looked at the internal construction of the switch module, and I think these switches may prove to be far more reliable than the old snap-action pushbuttons were; the contacts are smeared with an anti-oxidant grease. I suspect that contact oxidation was what made the snap-action switches become unreliable as they aged.

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FEEDBACK

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Lexmark T650 -- Transfer Roller Bearing, Right Side

A T650 came in the shop with a shattered right side transfer roller bearing. The P/N is 40X1888. (All variations of the T65X series use the same part -- Lexmark calls it the 'right transfer roll bracket assembly'.) Here's a view of an intact bearing.

That one claw at the rear end of the part can be a bit awkward to get out and back in. Apart from that, replacing one of these is a straightforward job. You'll need a stubby No. 2 Phillips screwdriver for the screw that holds this part in place. For a T650, proceed as follows:

1) Toner Cartridge

2) Paper Tray (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) Connection Access Cover
- Open it fully and its hinges can be popped free rearward.


6) Lower Rear Cover w/Fuser Access Door
- Three M3x10mm black washerhead threading screws.
- Open the fuser access door -- two claws.
- Pull the cover away at your left and slide the cover toward your right. A downward-pointing hook will slide off a lip at the rear of the chassis.
- NOTE: The above-mentioned hook makes this an awkward part to get back in place. You have to exactly re-create the cover's attitude as the hook was coming off to get it back on again.


7) 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.
- Tug at the front lip and two upper claws and one lower claw will pop free. The cover's rear hinges come away easily.

8) System PCA Pan Cover
- One M3x6mm black pan head screw at the upper rear.
- Loosen off five M3x6mm black pan head screws.
- Slide the cover forward slightly and pull it away over the screwheads.

9) MP Feeder Platform
- Flex the slide pins' ways to free the slide pins.
- Tip the platform up to vertical and pull it off its hinge pins.

10) MP Feeder Door
- Pry the support arms to pop their pins out of their ways.
- Slide the door leftward off its hinge pins.

11) Upper Deflector
- Pull the extreme left end of the piece toward you and force the deflector to the right. It can then be unhooked at the right end.
- NOTE that reinstallation of this item is complicated by a downward-projecting spike near its left side end. You really have to flex the thing to get it to go back into place.

12) MP Feeder Pickup Roller w/Slip Rollers
- One e-clip.

13) MP Feeder Lower Deflector/Elevator Flap Assembly
- Disconnect the sensor cable at J35 on the system PCA (blue connector).
- Two M3x12mm washerhead threading screws at the right side.
- Two M3x10mm washerhead threading screws at the left side. A flashlight is helpful for locating the upper one of these two.
- Pull the item away while extracting the sensor cable.

14) Inner Deflector
- Two tabs at lower front, left and right.
- Two upward-hooking claws near the upper rear; accessible through rectangular openings.

15) Transfer Roller

16) Set the machine on its back.

17) Toner Density Sensor
- One M3x10mm washerhead threading screw from underneath.
- Just move the sensor aside.

18) Right Side Transfer Roller Bearing
- One M3x8mm washerhead threading screw.
- Pry/force up the claw at the rear of the part.

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FEEDBACK

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Lexmark T63X -- Fuser Teardown/Overhaul Checklist

This document is a condensation of a procedure. It can serve as a checklist once one is familiar with all the information in the procedure.

1) Left Side Lamp Terminal Cover

2) Left Side Lamp Terminal

3) Lamp

4) Thermistor Cable

5) AC Spade Connector at the upper right of the top cover

6) Top Cover

7) Stripper Bar Torsion Springs

8) Exit Roller

9) Idler Gear

10) Pressure Roller Springs
- Unhook them at the lower front of the frame.

11) Ring Gear

12) Left Side Bearing

13) Hot Roller w/Bushings

14) Right Side Bearing

15) Input Ramp

16) Stripper Bar

17) Pressure Roller w/Bearings and Bearing Holders

- - -

At this point, you can proceed in either of two ways.

a) Carry on with the full procedure for a thorough overhaul.

b) Abbreviate the procedure for a 'good-enough' overhaul.
- Scrape the right side lamp contact.
- Blow out the lamp contact and the sensors w/compressed air.
- Apply a couple of drops of light mineral oil to the pressure roller arms' pivot points.
- Inspect the two sensors.
- Reassemble w/new parts A/R.

- - -

18) Output Ramp

19) Pressure Roller Springs

20) Right Side Pressure Roller Arm

21) Left Side Pressure Roller Arm and Link

22) Right Side Lamp Contact Assembly

23) PCA

24) Solenoid

26) Reassemble w/new parts A/R

- - -

Frequently Replaced Parts

Assembly, 115V Fuser, T630/632: P/N 56P2542 [was 56P1333]

Assembly, 115V Fuser, T634: P/N 56P2545 [was 56P1859]

Bearing, Hot Roll [6003Z: 17mm bore x 35mm O.D. x 10mm thick]: P/N 99A0143

Bearing, Pressure Roller [R3Z: 0.1875" bore x 0.500" O.D. x 0.196" thick]: P/N 99A1621

Pressure Roller: P/N 99A0158-CLT

Coated (Hot) Roller: P/N 99A2036-CLT

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FEEDBACK

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Lexmark T Series -- Broken Left Side Cover Hinge Pin

Pictured below is the site of a broken-off hinge pin on a T640 left side cover. I've 'punched' the centre of it with an awl in preparation for repairing it.


This is pretty easy to repair. Proceed as follows.

1) Drill 7/64" at the centre of the break.

2) Tap the hole 6-32.

3) Cut 1/2" off the end of a long 6-32 screw to make a 'setscrew'. File the cut end smooth and square. With a mini-hacksaw, cut a slot in the cut end to accept a jeweller's screwdriver.

4) Run the setscrew into the tapped hole. Leave 3/16" of the screw protruding.

5) Apply CA adhesive to the upper part of the screw and leave it awhile to set.

Here's how it looks when it's done.

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FEEDBACK

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