Revision 09, Discard Previous Copies

Printer Solutions & Services Division X65X ADF Screen Activity

Process Overview
Unbox
Adjust Skew
Replace Torque Limiter and rework the 4
ADF Top Cover bosses (pg 3)
Identify type of skew
Check main printer skew in Diagnostics
Menu (pg 7)
Repair if needed

Exit Diagnostics Mode

Negative skew Negative skew
Positive Bottom only
Check copy skew on Flatbed (pg 8). skew
Repair If needed (pg 9)

Check copy skew on Front ADF (pg 8).

Repair if needed (pg 10)
Try the following reworks, printing a test
page after each:
Check copy skew on Back ADF (pg 8). 1. Make sure front bracket is centered
Repair if needed (pg 9) pg 11
Try the following reworks, printing a test
page after each:
1. Shift front bracket left (4 screws)
pg 11

Check registration on Flatbed, Front

ADF, and Back ADF. Reset as needed
(spec on pg 8). 2. Shift entry pg 13
guide left pg 11 2. Rotate ADF
(2 screws) Tray clockwise
Adjust Registration (pg 15) or counter-
clockwise

3. Drop the
1. Enter the Config Menu
OK rear hinge pg 12
G 3. Raise or
Report Pass/Fail for: 2. Adjust front ADF, rear drop the pg 12
ADF, and flatbed rear hinge G
Skew Flatbed
Skew front ADF registration
Skew back ADF 4. Add the pg 12
Registration Flatbed NOTE: Skew will be worse spacer pg 12
Registration front ADF because the page is 4. Add the
duplexed from the Copy spacer
Registration back ADF pg 13
Multifeed Test Quick Test
5. Rotate ADF
Tray counter-
See pg 17 for the list of print clockwise
samples to save OK
pg 14

6. Add entry
Orion Copy Test guide shift
(pg 16) If an adjustment
Includes check for makes skew worse,
print defects from undo the change
transfer roll

Repackage and
Mark Box (pg 17) All skew adjustments must
be made in normal copy
mode with the front ADF
Rework After skew is fixed, cover installed
check registration
Complete

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Operation
Sequence UnBox Copy Skew and Multifeed Validation
Number Printer Event Activity
100 Technical level 1

20 Release white clips from bottom edge of printer box. Remove box from printer.

10 Set aside all kit items: printer pubs, line cord, accessories, box and cushions for reuse.
(NOTE: Top Carton MUST stay married to printer to ensure printer
is returned to correctly labeled box as assigned per serial number)

5 Carefully remove plastic bag and set aside for reuse.

5 Observe all taped locations.

10 Remove tape from locations that will allow the front cover and paper tray to be opened.
6 Adhere tape to sides of printer to allow for reuse.

35 Open front covers. Remove SWE cartridge and carefully remove cartridge internal packaging.
Set a side for reuse.

5 Remove Fuser Saver and set aside for reuse.

10 Reinstall SWE cartridge to printer and close front covers.

60 Remove all packaging from the scanner.

166

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Operation
Sequence Replace
Number Torque Limiter Event Activity
150 Technical level 1

40

Printers made after SEP 18, 2009 do

not need the Torque Limiter
replaced or the Top Cover reworked
because the issue was fixed at the
factory.

The replacement Torque Limiter may be a

different color than the original part. If there
is a black dot on the Torque Limiter, it does
NOT need to be replaced.

Female notch fits into Male

notch on the Sep Roll hub.

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Operation
Sequence ADF Cover Rework
Number Event Activity
150 Technical level 1

40 Remove the front ADF cover.

Be very careful with the 2 plastic snaps, they are delicate.
For the snap on the right, Insert a screwdriver in the hole and push the snap gently to release it.
The ADF Front Cover must be replaced for every skew measurement. If it not on place, the skew is terrible.

Remove the rear ADF cover.

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Operation
Sequence ADF Cover Rework
Number Event Activity
160 Technical level 1

Remove the ADF top door assembly

Open the ADF Top Cover
Unscrew the 2 hinge pins on the left and right side (C in the picture).

It's easiest to remove the Top Cover by freeing it from the sheet metal slots near the hinge pins. Then rotate the door like you
are closing the Top Cover and the white pieces (B in the picture) will fall out. They must be twisted to reinstall.

Be very careful when screwing in the hinge pins. The hinge pins must go into the pivot holes on the Top Cover. If they are not
installed properly, the Top Cover will not close correctly.
Operation
Sequence ADF Cover Rework
Number Event Activity
170 Technical level 1
1. Remove 4 screws as shown
2. Remove ADF Top Cover sub assembly
3. Use Product Engineering rework tool to modify 4 boss locations
Correct modification requires firm consistence application of force
Dependant on original boss height, material may or may not be removed in the rework process
4. Blow off any excess debris that could contaminate the ADF.
5. Re-assemble in reverse order

4
ADF Top Cover
3 Sub-assembly

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Operation
Sequence ADF Cover Rework
Number Event Activity
180 Technical level 1

Mark the Top Cover to show the rework is complete.

The final boss height can be checked with a scale.

It should be 14.7 +0.5 and -1.0 mm

Operation
Sequence Paper Load
Number Event Activity
200 Technical level 1

5 Remove Paper tray.

10 Verify Tray 1 Rear Slider is set accurately in the appropriate media position (Letter or A4) .
15 Using 150 to 200 sheets of standard media, fan the paper and carefully install into paper tray.
6 Verify the media is cut squarely, refer to the Media Squareness Check provided in additional worksheet
5 Verify right side Paper Restraint fits snuggly to the right edge of the paper stack.

Insert paper tray into printer.

41

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Operation
Sequence Print and Judge
Number Registration Page Event Activity
300 Technical level 1

60 Plug printer into power source and power on in Diagnostics Mode (hold down 3 and 6 during POR).
35 Select "Registration"
Select "Quick Tests"
95 The printer Registration page will print.

310 Technical level 2

60 Measure L1, L2, T1, T2, R1, R2, B1, and B2 data points as shown below.
Record the values on the registration page and the excel file (Skew Measurement Data file.xls) provided for data capture.

45 Determine the following calculations : L2-L1 = ___

R2-R1 = ___
T2-T1 = ___
B2-B1 = ___

15 Determine if the printer passes or fails the skew specification, based upon the values listed in the green box below.

If printer meets Skew Specification, proceed to Operation 400

5 If printer fails Skew Specification, attach a "Quality Hold' piece of paper onto Top Carton, and proceed to Operation 1100

125

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400 Technical level 2
60 Copy Skew and Registration Specification

60 Plug printer into power source and power on in Normal Printing Mode.
Measure CopyL1, CopyL2, CopyT1, CopyT2, CopyR1, CopyR2, CopyB1, and CopyB2 data points as shown below.
Record the values on the registration page and the excel file (Skew Measurement Data file.xls) provided for data capture.
60 Determine the following calculations: CopyL2-CopyL1 = ___
CopyR2-CopyR1 = ___
CopyT2-CopyT1 = ___
CopyB2-CopyB1 = ___
CopyT1-CopyB1 = ___
CopyL1-CopyR1 = ___
15 Determine if the printer passes or fails the skew specification, based upon the values listed in the yellow box below.

CopyT1 CopyT2

CopyL1 CopyR1

For letter paper

Copy Skew Spec
Measurement Spec Description
(CopyL2-CopyL1) ≤ 2.0 mm Left Skew
(CopyR2-CopyR1) ≤ 2.0 mm Right Skew
(CopyT2-CopyT1) ≤ 1.5 mm Top Skew
(CopyB2-CopyB1) ≤ 1.5 mm Bottom Skew

Copy Registration Spec

Measurement Spec Description
(CopyT1-CopyB1) ≤ 1.5 mm Vertical Registration
(CopyL1-CopyR1) ≤ 2.0 mm Horizontal Registration

CopyL2 CopyR2

CopyB1 CopyB2

This spec is to be used for the Flatbed, Front ADF, and Back ADF.
195

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 Plug printer into power source and power on in Normal Printing Mode.
30 Check the flatbed skew and registration.
Place the IQT master sheet onto the flatbed and make a copy.
Use the same requirements.
If the printer does not meet the spec, adjust the flatbed skew using the procedure from the service manual, shown below.

30 Check the front side ADF

Load the IQT master sheet into the ADF tray face up
Adjust the side restraints on the ADF to fit snuggly.
Press the green button to make a copy of the page.
The copy will print.

255 If printer meets all Copy Skew and Copy Registration Specs, proceed to Operation 700
If printer fails front Front ADF Copy Skew Spec, attach a "Quality Hold' piece of paper onto Top Carton, and go to Operation 500
If printer fails Registration Specs, attach a "Quality Hold" piece of paper onto the Top Carton, and proceed to Operation 600

30 Check the back side ADF skew and registration

Place the IQT master sheet on the ADF face down.
Use the Copy menu to make a 2-sided to 1-sided copy.
Adjust the side restraints on the ADF to fit snuggly.

Evaluate the skew and registration, use the same requirements.

If the printer does not meet the requirements, adjust the back side ADF skew, see below.

Some of the adjustments for Front Side ADF skew can change the Back Side ADF skew, so it must be checked
again after adjusting the Front Side ADF.

2. Adjust Screw

1. Loosen Screw
3. Retighten Screw

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Operation Front ADF Skew
Sequence Rework
Number Event Activity
500 Technical level 3
NOTE: Some of these steps will make skew better and some will make it worse. The order listed below has worked on many
printers, but it is not perfect. If any of these steps make skew much worse, undo it and move on to the next step.

NOTE: Many of the adjustments for skew can effect the ADF registration, so it must be checked again after the skew repair.

1. Copy the IQT sheet

40 2. Remove the front ADF cover.

Be very careful with the 2 plastic snaps, they are delicate.
For the snap on the right, Insert a screwdriver in the hole and push the snap gently to release it.
The ADF Front Cover must be replaced for every skew measurement. If it not in place, the skew is terrible.

NOTE: To speed up the rework, it is recommended that skew be visually checked by folding the page in half and holding it up to a
light for observation. The final page should be measured to confirm it meets the skew and registration specs.

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 Front Bracket Position

30 For Negative top edge copy skew:

1. Remove the ADF front cover.
2. Check to see if the plastic boss is centered in the hole.
If the boss is centered, move on to the next step "Shift the Entry Guide Left"

3. If the boss is not centered in the hole, loosen the 4 screws on the metal piece on the front side of the ADF and retighten
40 with the boss centered.

It is critical to maintain the up/down position of the boss in the hole or skew can get much worse.

Loosen screws Pull this side of the

plate slightly toward
40 3. Snap the ADF front cover into place. The screws are not needed yet.
30
4. Copy the IQT page and observe the skew. this is the IQT master page
30 If the copy meets the Copy Skew Spec, install the screws on the covers and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

For Negative bottom edge copy skew and Positive copy skew

10 1. Loosen the 4 screws and shift Front Bracket to the Left

Original Position Position to fix

positive Skew

Shift the metal plate to

the left. Be sure to
maintain the vertical
position.

It is critical to maintain the up/down position of the boss in the hole or skew can get much worse.

40 3. Snap the ADF front cover into place. The screws are not needed yet.
30
4. Copy the IQT page and observe the skew.
30 If the copy meets the Copy Skew Spec, install the screws on the covers and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

5. If this change made skew worse, undo it. In rare cases, skew can be improved by biasing the metal plate to the right.

Shift the Entry Guide Left

30 1. Loosen 1 screw and remove the other.
Push the plastic boss out of the hole in the metal plate. Push the gray plastic piece to the left, see picture below.
Tighten both screws while pushing the assembly left.

Loosen Screw

Remove Screw Move boss to the

left to expose as
much hole as
possible

NOTE: Make sure both screws were tightened.

30 2. Snap the ADF front cover into place. The screws are not needed yet.

30 3. Copy the IQT master page and observe the skew.

If the copy meets the Copy Skew Spec, install the screws on the cover and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

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 Reduce the Gap at the Rear Hinge
1. Remove the Back ADF Cover

30 2. Measure the gap shown below. Generally a reduction from approximately 2 mm to approximately 1.5 mm can improve skew.
20 If this gap is made too small, it is noisy or difficult to lift the ADF off the flatbed. Make sure it can open freely.

Rotate screw to l
ower ADF and re
duce gap

Gap

3. Make sure the ADF front cover is in place. The ADF back cover can be left off. The screws are not needed yet.
30
4. Copy the IQT page and observe the skew.
30 If the copy meets the Copy Skew Spec, install the screws and covers and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

WARNING: This repair, when combined with "Shift the Entry Guide Left", can stretch the image along the length of the page.
The registration at the bottom can be severely out of spec. In this case, move the entry guide back to the original position.

5. If this change did not help, try adding the ADF spacer (next step).

ADF Spacer

10 1. Add a 2 mm spacer under the contact point shown in the picture below.
Use a USA nickel (it must be a 2 mm spacer, other American coins should not be used) under this point before adding an
adhesive pad to see if it helps.

Location for the

Felt Spacer

15 2. If the nickel spacer works, add a stick-on felt spacer to the area shown.

3. Make sure the ADF front cover is in place. The ADF back cover can be left off. The screws are not needed yet.

30 4. Copy the IQT page and observe the skew.

If the copy meets the Copy Skew Spec, install the screws on the covers and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

WARNING: This repair, when combined with "Shift the Entry Guide Left", can stretch the image along the length of the page.
The registration at the bottom can be severely out of spec. In this case, move the entry guide back to the original position.

5. If Reducing the Rear Gap and adding the ADF Spacer made skew worse, undo these changes and continue with the repair.

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 Rotate the ADF Tray (only if nothing else works)

5 1. Note the location of the ADF Tray in the screw slots.

10 2. Loosen the screw on 1 side and rotate the ADF tray a small amount (approximately 1 to 2 mm).
30 3. Copy the IQT sheet to see any effect and iterate as needed.
Use very small adjustments for the ADF tray. This should be a last resort because it will effect the Back Side ADF skew.

If the ADF Scan

10 image shows left
Negative top corner is Positive
If top right corner of
Skew higher than the Skew the scan is higher
right, adjust the than the left, rotate
5 ADF TRAY by the tray to the
rotating it anti- clockwise
clockwise.

35

< Before ADF TRAY rotation> < After ADF TRAY rotation>

30 3. Copy the IQT page and observe the skew.

If the copy meets the Copy Skew Spec, install the screws on the covers and go to Operation 400.
If the copy does not meet the Copy Skew Spec, continue the repair.

Check

If the skew is not fixed, check the entry guide shift and other fixes to make sure they were not disturbed during repair.

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 Add the Entry Guide Bracket

30 1. Loosen 1 screw and remove the other.

Loosen the small black screw shown below.

Loosen screw

Remove and
discard this screw

Loosen the black

screw

2. Insert the entry guide bracket in the position shown below.

3. Push the bracket to the left. This adjustment is very sensitive and only a tiny shift is needed.

Entry guide
bracket installed

The hole is used to see the

bracket position

NOTE: Make sure all 3 screws are tightened.

30
2. Snap the ADF front cover into place. The screws are not needed yet.
30 3. Copy the IQT master page and observe the skew.

NOTE:The bracket can cause the image to shift down the page and stretch it along the length of the page.
If it is shifted too far, the printer can fail the ADF registration adjustment requirements.

If the copy meets the Copy Skew Spec, install the screws on the cover and go to Operation 400.
If the copy does not meet the Copy Skew Spec, go back and check several printer registration pages to verify the main
printer skew. Also check the paper squareness.

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Operation
Sequence ADF Registration
Number Rework Event Activity
600 Technical level 2

60 Plug printer into power source and power on in Config Mode (hold down 2 and 6 during POR).
Copy the IQT sheet and observe the registration error.
35
Under the Manual Scanner Registration menu, adjust the front ADF registration.

30 Do a Copy Test
The copy test is duplexed so it's normal for skew to be worse than the spec at the top and bottom.

30 Observe the registration.

If the copy meets the ADF Registration Spec, go to Operation 700.
If the copy does not meet the ADF Registration Spec, continue adjusting.

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Operation
Sequence Print Quality
Number Test Event Activity
700 Technical level 1
Plug printer to power and Orion operation. (USB cable)
Power on the printer
From the Orion screen choose "Copy Test" application.

Continue through Orion prompts to

-Check the print quality for defective transfer rolls. SEE THE PICTURE BELOW.
If a print defect is observed, the printer fails the print quality test. Replace the transfer roll and repeat Orion.

-Reset page count

-Reset cartridge paddle wheel
-Prepare printer for shipment

Verify test complete and pass. Go to Operation 900.

Defective transfer rolls

have oval shaped print
defects spaced 51.7 mm
(or 2.04 in.) apart.

Poor print quality across the width

of the page is common in extremely
humid environments. It will
disappear under normal operating
conditions.

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Operation
Sequence Prepare for
Number Re-Packaging Event Activity
900 Technical level 1

5 Power off printer and remove power cable from power source.
5 Open paper tray and ensure all paper is removed.

5 Remove SWE Cartridge from printer

10 Reinstall Fuser Saver.

Ensure smiley face is in upward position

25 Re-install SWE Cartridge packaging.

10 Re-install SWE Cartridge to printer

30 Record Printer SN from label located on the inside printer frame onto a Kit Check validation Sheet

2 Close front cover

92

For each printer, staple together and save the following pages:
Printer registration page (with Serial Number)
Out of box Flatbed If the skew and registration
Out of box Front ADF are OK, the out of box print
Out of box Back ADF sample will be the same
Final Flatbed page as the final print
Final Front ADF sample.
Operation Prepare for
Sequence
Final Back ADF
Number Re-Packaging Event Activity
1000 Technical level 1

60 Visually inspect for any blemishes - clean surfaces with damp cloth as needed.
10 Replace any previously removed tape.
20 Slide plastic bag over printer
5 Replace Tape onto bag
60 Use Kit Check validation Sheet to ensure all accessories are in place
20 Replace Top Carton over printer, ensuring Top Cushion is in proper position
5 Ensure SN on Kit Check validation Sheet and Carton Label match
20 Replace Carton locks
140

Number Event Activity

1100 Technical level 1

Skew OK, Top If printer meets the ADF Skew and Registration specification and had the Top Cover Bosses reworked mark
Cover reworked the A3 Quality Grid location.
==> Place a blue dot (label or marker) on "A3" of the Quality Grid located on the Carton Label

Skew OK, Top If printer meets the ADF Skew and Registration specification, had the Top Cover Bosses reworked, and the torque
Cover reworked and limiter replaced, mark the A3 Quality Grid location.
Replaced Torque Lim. ==> Place a green dot (label or marker) on "B3" of the Quality Grid located on the Carton Label

10

10

Rework Process If printer fails Skew Specification

FAILS ==> Ensure that a "Quality Hold" piece of paper is attached to Top Carton after the printer is reboxed.
These printers will remain in an NCM location on Quality Hold for future rework defined by Lexmark Engineering.

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