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IBM InfoPrint 20

Service Guide

Document Number: G544-5514-01

Note Before using this information and the product it supports, be sure to read the general information in Notices on page 5.

Second Edition (August 1998) This edition applies to Release 2.0 of the IBM InfoPrint 20 Service Guide, G544-5514-01. The following paragraph does not apply to any country where such provisions are inconsistent with local law. INTERNATIONAL BUSINESS MACHINES CORPORATION 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. Order publications through your IBM representative, your IBM Printing Systems Company printing specialist, or the IBM branch office serving your locality. Publications are not stocked at the address given below. IBM Printing Systems Company home page: http://www.printers.ibm.com IBM and the IBM Printing Systems Company welcome your comments. Either fax your comments to 1-303-924-6873, e-mail them to PRINTPUB@US.IBM.COM, or mail them to: Department H7FE, Building 003G The IBM Printing Systems Company Information Development P.O. Box 1900 Boulder, CO 80301-9191, U.S.A. When you send information to IBM, you grant IBM a non-exclusive right to use or distribute the information in any way it believes appropriate without incurring any obligation to you. Copyright International Business Machines Corporation 1998. All rights reserved. Note to U.S. Government UsersDocumentation related to restricted rightsuse, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corporation. Copyright International Business Machines Corporation 1998. All rights reserved. Note to U.S. Government Users Documentation related to restricted rights Use, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp.

Master Table of Contents


Notices on page 5 About This Book on page 23 Chapter 1. Getting Started on page 25 Chapter 2. Diagnosing Problems on page 37 Chapter 3. Diagnostic Tools on page 247 Chapter 4. Circuit Diagrams on page 307 Chapter 5. Locations on page 360 Chapter 6. Removal Procedures, Adjustments on page 394 Chapter 7. Preventive Maintenance and Usage Kit on page 543 Chapter 8. Parts Catalog on page 544 Appendix A. Features on page 589 Appendix B. Supplies on page 591 Appendix C. Media Specications on page 593 Appendix D. Technical Support on page 602 Appendix E. Duplex Unit Option on page 604 Appendix F. Envelope Tray Option on page 658
Copyright IBM Corp. 1998

Appendix G. 500-Sheet Paper Tray Option on page 661 Appendix H. 2000-Sheet Input Drawer Option on page 703 Index on page 788

Master Table of Contents 4

Notices
References in this publication to IBM products, programs or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service is not intended to state or imply that only IBMs product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any of IBMs intellectual property rights may be used instead of the IBM product. Evaluation and verication of operation in conjunction with other products, except those expressly designated by IBM, is the users responsibility. Any performance data contained in this document was obtained in a controlled environment based on the use of specic data. The results that may be obtained in other operating environments may vary signicantly. Users of this document should verify the applicable data in their specic environment. Therefore, such data does not constitute a performance guarantee or warranty. IBM may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not give you any license to these patents. You can send license inquiries, in writing, to the IBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.

Copyright IBM Corp. 1998

Safety Notices
There are three levels of safety notices: DANGER, CAUTION, and Attention.

Danger Notices
The word Danger indicates the presence of a hazard that has the potential of causing death or serious personal injury. Danger notices are numbered <1-10>, <1-11>, and so forth where they appear in the text of this manual. Use the notice number to locate the national language translation of that notice in the IBM InfoPrint 20: Safety Instructions. Example danger notice:

Notices 6

Caution Notices
The word Caution indicates the presence of a hazard that has the potential of causing moderate or minor personal injury. Caution notices are numbered <2-20>, <2-21>, and so forth where they appear in the text of this manual. Use the notice number to locate the national language translation of that notice in the IBM InfoPrint 20: Safety Instructions. Example caution notice:

Notices 7

Safety Precautions Disposal of Materials

Electrical Safety
This printer is inspected and listed by recognized national testing laboratories, such as Underwriters Laboratories, Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in design and manufacture. Remember, however, that this product operates under conditions of high electrical potentials and heat generation, both of which are functionally necessary. Because the paper and toner used in the printer can burn, take normal precautions to prevent re. These precautions include common-sense measures, such as keeping potentially combustible materials (for example, curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limiting unattended

Notices 8

operation, and having trained personnel available and assigned to the printer.

Notices 9

Laser Safety
This printer complies with the performance standards set the by U.S. Food and Drug Administration for a Class 1 Laser Product. This means that the printer belongs to a class of laser products that does not produce hazardous laser radiation in a customer access area. This classication was accomplished by providing the necessary protective housing and scanning safeguards to ensure that laser radiation is inaccessible or within Class 1 limits. There are various tool-operated machine covers that should be moved, removed, or replaced only by trained service personnel. There are no operator controls or adjustments associated with the laser. No operator maintenance is required to keep the product in compliance as a Class 1 Laser Product. No adjustments that affect laser operation or power are accessible to the operator. See the IBM InfoPrint 20: Safety Instructions for national language translations regarding laser safety.

Notices 10

Ozone Safety
An innitesimal amount of ozone gas (O3) is generated during corona discharge from the transfer charge roller. The ozone gas is emitted only when the printer is operating. This printer meets the ozone emission reference value set by Underwriters Laboratory (UL) at the time it is shipped from the factory.

Toner Safety
Toner is a non-poisonous substance composer of minute, plastic components. If toner adheres to your skin or to your clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hot water, the toner will gel and become difficult to remove. As toner easily breaks down vinyl materials, avoid letting toner come into contact with vinyl.

Notices 11

Safety Inspection
See Danger Notices on page 6 and Caution Notices on page 7 for an explanation of these notices.

Instructions
Perform a safety inspection before performing any of the following tasks: v Accepting a machine for a service agreement v Providing per-call service v Relocating a machine v Reviewing changes or attachments on any IBM machine that is leased, on service agreement, or on per-call service Correct unsafe conditions before you continue. Possible safety hazards are: v ElectricalAn electrically charged frame, or exposed wires or connections, can cause serious electrical shock. v MechanicalA missing safety cover or shield is hazardous. Moving parts, such as gears, shaft, and pulleys are hazardous. v ChemicalUse only approved cleaning agents. Do not use other solvents or chemicals.

Notices 12

Reference Items
You need the following items: v A copy of the machine EC history v Electrical Safety for IBM Customer Engineers, S229-8124

Printer Safety Inspection


1. Switch off printer power and unplug the power cord from the wall. 2. Perform the Power-Receptacle Safety-Check on page 17. 3. 4. 5. 6. 7. Ensure that all cables are disconnected from the printer. Ensure that the correct power cord is used. Inspect the power cord for wear or damage. Ensure that the machine is steady. Remove all covers and access panels (see Chapter 6. Removal Procedures, Adjustments on page 394).

8. Inspect the covers and access panels for damage. 9. Ensure that all warning labels are in place. 10. If you are placing this printer on a service contract with IBM, check for changes not made by IBM. If you nd changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBM branch office. Complete the form and return it to the branch office. 11. Ensure that all ground connectors are correctly connected and tight (see Figure 1 on page 15 and Figure 2 on page 16.) 12. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. The reading must not exceed 0.1 ohm. 13. Inspect all cables, connections, and plugs for worn or damaged wiring.

Notices 13

14. Check for signs of contamination, corrosion, smoke, or burning. If there are signs of smoke or burning, check the Maintenance Agreement Qualication (MAQ) form for the correct repair procedure. 15. Replace all covers and access panels. The printer system diagram and ground locations are shown below. For a detailed description of the signals, see Chapter 4. Circuit Diagrams on page 307.

Notices 14

(ROS ASSEMBLY) (LD ASSEMBLY) LD


(CRU SENSOR ASSEMBLY) LD SWITCH

(SCANNER ASSEMBLY)
SCANNER MOTOR FG

5VDC (MCU PWB) (MAIN MOTOR)

(FUSER COVER SWITCH)

INTERLOCK DETECTION LOGIC

SG

(HVPS)

(FUSER ASSEMBLY) TEMPERATURE SENSOR ASSEMBLY (HEATER ROD) THERMOSTAT THERMAL FUSE

FUSER CONTROL LOGIC

HEATER ASSEMBLY

SG

(INTERLOCK SWITCH)

ACN

ACL

(INTERLOCK SWITCH) (LVPS ASSEMBLY)


5VDC SG
HEATER CONTROL

RTN FAN FAST

FAN ALARM

FEED BACK OUTPUT


CONTROL

5VDC SUPPLY

24VDC

(FAN)
AC L FUSE

24VDC SUPPLY

FAN CONTROL

FAN ON

AC N POWER SWITCH FG SG

RTN

hc2m004F
FG

Figure 1. IBM InfoPrint 20 System Diagram and Ground Locations

Notices 15

Screw, Star Washer

Lug
hc2m131F

Typical GND Detail

Figure 2. Ground Connector Detail

Notices 16

Power-Receptacle Safety-Check

See Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and procedures before performing any of the following tasks. (Electrical Safety for IBM Customer Engineers, S229-8124 may not be applicable for other countries): v Checking ac voltage at the power receptacle v Checking ac impedance to ground at the power receptacle Perform the power receptacle safety check as described in Electrical Safety for IBM Customer Engineers, S229-8124. Use only the applicable high-voltage probes. See the applicable table below for the permitted ac voltage range and record the voltage measured: v See Table 1 on page 18, Nominal AC Line Voltages at Power Receptacle (110 V ac120 V ac) v See Table 2 on page 18, Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac) v See Table 3 on page 19, Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac, 3 Phase Wye Connected)

Notices 17

Do not continue until the voltages are in the correct range.


Table 1. Nominal AC Line Voltages at Power Receptacle (110120 V ac)
Nominal Line Voltages 100, 110, 120, and 127 V ac Phase to Neutral 50 Hz 90119 V ac 60 Hz 90137 V ac 50 Hz 90119 V ac 60 Hz 90137 V ac <1.0 V ac Recorded Line Voltages V ac V ac V ac V ac V ac

Phase to Ground Ground to Neutral

Table 2. Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac)


Nominal Line Voltages 200, 208, 220, 230, and 240 V ac Phase A to Ground Phase B to Ground Phase A to Phase B 90137 V ac 180254 V ac 50 Hz 180259 V ac 60 Hz 180254 V ac Recorded Line Voltages V ac V ac V ac V ac

Notices 18

Table 3. Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac, 3 Phase Wye Connected)
Nominal Line Voltages 3-Phase Wye Connected 200, 208, 220, 230, and 240 V ac Phase to Neutral 50 Hz 180259 V ac 60 Hz 180254 V ac 50 Hz 180259 V ac 60 Hz 180254 V ac <1.0 V ac Recorded Line Voltages V ac V ac V ac V ac V ac

Phase to Ground Ground to Neutral

Notices 19

Electrostatic Discharge (ESD) Procedures


Attention: If discharged into the circuitry of an integrated circuit, static electricity can damage the circuit. Follow these procedures to prevent damage to ESD-sensitive components; 1. Use the ESD Kit. a. Turn off the printer before you put on the ESD wrist band. b. Connect the wrist band to an unpainted, frame-ground point of the printer. c. Remove the ESD wrist band when working on any part of the printer that has power turned on. d. Do not put the ESD mat near any electrical circuit that has power turned on. The internal resistance (1 megaohm) in the ESD cable limits the current if it touches a high voltage. e. Do not put the ESD mat near a grounded surface. Ground the ESD mat only through the ESD cable. The ESD cable supplies a high resistance to ground for your safety. If the ESD mat touches a grounded surface, the high resistance in the ESD cable is bypassed, which causes the ESD mat not to work as expected. 2. Keep an ESD-sensitive part in its original shipping container, usually a protective bag, until you are ready to install it. 3. Make the fewest possible movements to minimize static electricity. 4. Touch the metal frame of the printer or the assembly to discharge static electricity in your body before touching the ESD-sensitive part. 5. Hold the ESD-sensitive part by its edges. Do not touch any components, pins, or connectors. If possible, keep one hand on the frame while you are installing or removing an ESD-sensitive part. 6. Do not place an ESD-sensitive part on anything that can provide a discharge path from your body through the ESD-sensitive part. If you need to put down the ESD-sensitive part, rst put it into the ESD protective wrapper in which it was shipped. 7. Prevent other persons from touching ESD-sensitive parts.

Notices 20

8. Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working with connectors. 9. Be careful when working with ESD-sensitive parts when the humidity is low. Low humidity increases static electricity.

Notices 21

Trademarks
The following terms are trademarks of the IBM Corporation in the United States or other countries or both: AIX AIX/6000 IBM InfoPrint OS/2 Personal System/2 PS/2 RISC System/6000 WIN-OS/2 The following terms are trademarks or registered trademarks of other companies:
Acrobat Adobe Adobe logo Apple Apple logo Ethernet Macintosh Microsoft Mylar Novell PostScript UNIX Windows Adobe Systems, Inc. Adobe Systems, Inc. Adobe Systems, Inc. Apple Computer, Inc. Apple Computer, Inc. Xerox Corporation Apple Computer, Inc. Microsoft Corp. E. I. du Pont de Nemours & Co., Inc. Novell Inc. Adobe Systems, Inc. AT&T Corporation Microsoft Corp.

Copyright IBM Corp. 1998

22

About This Book


This book is designed to help you service the IBM InfoPrint 20. It describes how to: v Dene and solve problems with the printer v Diagnose printer problems v Service the printer v Locate printer components v Remove and replace printer components v Identify printer parts for repair and procurement v Diagnose and repair electrical problems v Perform preventive and periodic maintenance

Copyright IBM Corp. 1998

23

Related Publications
To obtain additional copies of this book or of any related publication, contact your IBM service representative, your authorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755 or 1-919-713-4055.
Document These service documents must be ordered separately: v IBM InfoPrint 20: Service CD-ROM. The Service CD-ROM includes the service guide for the IBM InfoPrint 20, as well as the customer documents that ship with the printer. These documents are viewable using Adobe Acrobat Reader, which is included on the CD-ROM. v IBM InfoPrint 20: Service Guide (Hardcopy) These books are included with the printer: v IBM InfoPrint 20: Users Guide v IBM InfoPrint 20: Quick Setup Poster v IBM InfoPrint 20: Safety and Warranty Information These books are included with the optional network cards: v IBM Network Printers: Ethernet and Token Ring Conguration Guide v IBM Network Printers: Twinax and Coax Conguration Guide These technical references must be ordered separately: v IBM Network Printers: PCL5e and PostScript Level 2 Technical Reference v IBM Network Printers: IPDS and SCS Technical Reference S544-5344 S544-5312 G544-5240 G544-5241 S544-5516 S544-5515 G544-5524 GK2T-9265 Number

G544-5514

About This Book 24

Chapter 1. Getting Started


Introduction . . . . . . . . . . . . . . Dening the Problem . . . . . . . . . Solving the Problem . . . . . . . . . . Diagnostic Quick Path . . . . . . . . Error Codes and Messages . . . . . Error Codes 0019 and Messages Error Codes 2049 and Messages Error Codes 5099 and Messages Print Quality Problems . . . . . . . . Print Quality Defects . . . . . . . . Miscellaneous, Routine Tasks . . . . . Completing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 26 28 28 30 30 31 32 33 34 35 36

Introduction
Chapter 1. Getting Started quickly guides you through problem isolation. Dening the Problem on page 26 reviews the information necessary to accurately dene any printer problem. With your printer problem dened, Diagnostic Quick Path on page 28 directs you to the correct diagnostic or repair procedure. See Miscellaneous, Routine Tasks on page 35 for miscellaneous or routine tasks. Completing Service on page 36 is a quality-of-service assurance checklist.

Copyright IBM Corp. 1998

25

Dening the Problem


Use the following as a guide for gathering information about the problem. 1. Discuss the problem with the operator. Note information such as error messages, other symptoms (such as print quality problems), what happened, what type of print job, and other recent problems. Review the printer history with the customer and obtain or print a printer conguration page (see Conguration Page on page 250). 2. Switch on printer power. The printer performs a start-up diagnostic routine that checks the printer controller and the printer. Almost all failures occurring during this start-up diagnostic routine and during WARM UP cause either an error code or a message. 3. Observe the display on the operator panel. Note: See Status Messages on page 239 for messages displayed during normal operation. v Is information correctly displayed? v Is the display blank, or does it display solid rectangles within approximately 2-minutes after power is switched on? v Does WARMING UP display? v Does READY display within approximately 2-minutes? v Is there an error code or message? v View or print the error log looking for recent problems or patterns. See Error Log on page 254 for a description of the error log. v Try to duplicate the failure noting the following: The printer fails to print a test print when not connected to a workstation or a network. The printer fails to print when connected to a workstation, or an Ethernet, token-ring, coax, or twinax conguration. The printer prints, but the paper jams.
Chapter 1. Getting Started 26

The printer prints, but has poor print quality. Using this information, go to Diagnostic Quick Path on page 28.

Chapter 1. Getting Started 27

Solving the Problem Diagnostic Quick Path


Using the problem information that you have gathered, go to Table 4 on page 29 below. Select the Symptom and Indication that most nearly denes your printer problem, and then Go To... the suggested item to isolate the failure. See Dening the Problem on page 26 for a review of the information necessary to accurately dene any printer problem. Note: See Status Messages on page 239 for messages displayed during normal operation.

Chapter 1. Getting Started 28

Table 4. Diagnostic Quick Path


Symptom Error codes 0019 Error code with a message Error codes 2049 Error codes 5099 WARMING UP (Always On) Message with No Error Code I/O INITIALIZING (Always On) IBM INFOPRINT 20 (Always On) Print quality problem Operator panel (blank, light or dark rectangles, pushbuttons), controller, or power problems Problems printing from a Ethernet/Token-Ring conguration Other Problems printing from a Twinax/Coax conguration EP (toner) cartridge is out of toner, and an error code 02 TONER LOW not displayed Intermittent or Random Problems Miscellaneous, routine tasks Environmental problem (temperature, humidity, ventilation, space, supplies storage) Indication Table 5 on page 30 Table 6 on page 31 Table 7 on page 32 Operator Panel, Controller, and Power Problems on page 135 Ethernet / Token-Ring NIC Printing Problems on page 150 Operator Panel, Controller, and Power Problems on page 135 Table 8 on page 34 Operator Panel, Controller, and Power Problems on page 135 Ethernet / Token-Ring NIC Printing Problems on page 150 Twinax / Coax NIC Printing Problems on page 179 Toner Low and No Error Code 02 Displayed on page 142 Intermittent or Random Problems on page 133 Table 9 on page 35 IBM InfoPrint 20: Users Guide Go To...

Chapter 1. Getting Started 29

Error Codes and Messages


Note: See Status Messages on page 239 for status messages displayed during normal operation.

Error Codes 0019 and Messages


From Table 5, select the Error Code Message , and then Go To ... the suggested procedure to isolate the problem.
Table 5. Error Codes 0019 and Messages
Error Codes 0019 and Messages Error Code Message 02 TONER LOW 03 2000 SHEET INPUT COVER OPEN 04 TONER CART MISSING 06 TOP COVER OPEN 09 DUPLEX COVER OPEN 10 FUSER COVER OPEN 11 LOAD <size> IN <source> Go To... 02 TONER LOW on page 46 03 2000 SHEET INPUT COVER OPEN on page 49 04 TONER CART MISSING on page 50 06 TOP COVER OPEN on page 52 09 DUPLEX COVER OPEN on page 54 10 FUSER COVER OPEN on page 55 11 LOAD <size> IN <source> on page 58 Error Codes 0019 and Messages Error Code Message 12 MANUALLY LOAD paper_size IN AUX 14 ADJUST PAPER GUIDES IN TRAY n 15 2000 SHEET INPUT NOT READY 16 TRAY n MISSING 17 TRAY OPTION ERROR 17 2000 SHEET INPUT ERROR Go To... 12 MANUALLY LOAD paper_size IN AUX on page 64 14 ADJUST PAPER GUIDES IN TRAY n on page 64 15 2000 SHEET INPUT NOT READY on page 64 16 TRAY n MISSING on page 65 17 TRAY OPTION ERROR on page 68 17 2000 SHEET INPUT ERROR on page 68

Chapter 1. Getting Started 30

Error Codes 2049 and Messages


From Table 6, select the Error Code Message , and then Go To ... the suggested procedure to isolate the problem.
Table 6. Error Codes 2049 and Messages
Error Codes 2049 and Messages Error Code Message 20 PAPER JAM 21 PAPER JAM 22 PAPER JAM 23 PAPER JAM 24 PAPER JAM 26 PAPER JAM 27 PAPER ERROR <source> 29 OUTPUT FULL 30 MEMORY OVERFLOW Go To... 20 PAPER JAM on page 69 21 PAPER JAM on page 73 22 PAPER JAM on page 83 23 PAPER JAM on page 84 24 PAPER JAM on page 89 26 PAPER JAM on page 94 27 PAPER ERROR <source> on page 94 29 OUTPUT FULL on page 98 30 MEMORY OVERFLOW on page 101 Error Codes 2049 and Messages Error Code Message 31 MEMORY ALLOC ERROR 32 PRINT OVERRUN 40 MEMORY OPTION ERROR 41 NETWORK OPTION ERROR 42 NETWORK OPTION ERROR 43 PS OPTION ERROR 44 IPDS OPTION ERROR 45 OPTION ERROR 46 NETWORK OPTION ERROR Go To... 31 MEMORY ALLOC ERROR on page 101 32 PRINT OVERRUN on page 101 40 MEMORY OPTION ERROR on page 101 41 NETWORK OPTION ERROR on page 102 42 NETWORK OPTION ERROR on page 102 43 PS OPTION ERROR on page 103 44 IPDS OPTION ERROR on page 103 45 OPTION ERROR on page 104 46 NETWORK OPTION ERROR on page 104

Chapter 1. Getting Started 31

Error Codes 5099 and Messages


From Table 7, select the Error Code Message , and then Go To ... the suggested procedure to isolate the problem.
Table 7. Error Codes 5059 and Messages
Error Codes 5099 and Messages Error Code Message 50 ERROR CALL FOR SERVICE 51 ERROR CALL FOR SERVICE 52 ERROR CALL FOR SERVICE 53 ERROR CALL FOR SERVICE 54 ERROR CALL FOR SERVICE 55 ERROR CALL FOR SERVICE 56 ERROR CALL FOR SERVICE 61 ERROR CALL FOR SERVICE 62 ERROR CALL FOR SERVICE 63 ERROR CALL FOR SERVICE Go To... 50 ERROR CALL FOR SERVICE on page 105 51 ERROR CALL FOR SERVICE on page 108 52 ERROR CALL FOR SERVICE on page 109 53 ERROR CALL FOR SERVICE on page 114 54 ERROR CALL FOR SERVICE on page 119 55 ERROR CALL FOR SERVICE on page 120 56 ERROR CALL FOR SERVICE on page 122 61 ERROR CALL FOR SERVICE on page 123 62 ERROR CALL FOR SERVICE on page 123 63 ERROR CALL FOR SERVICE on page 124 Error Codes 5099 and Messages Error Code Message 71 DISK ERROR 72 DISK ERROR 73 DISK ERROR 80 ADD MEMORY FOR IPDS 80 ADD MEMORY FOR PAGES, ESC/P 81 INSUFFICIENT MEMORY FOR IPDS 81 INSUFFICIENT MEMORY FOR PAGES 82 CX SEND STATE 83 CX SEND STATE 84 NO FONT SIMM FOR PAGES, ESC/P Go To... 71 DISK ERROR on page 124 72 DISK ERROR on page 124 73 DISK ERROR on page 125 80 ADD MEMORY FOR IPDS on page 125 80 ADD MEMORY FOR PAGES, ESC/P on page 125 81 INSUFFICIENT MEMORY FOR IPDS on page 125 81 INSUFFICIENT MEMORY FOR PAGES on page 125 82 HOST TIMEOUT on page 126 83 CX SEND STATE on page 126 84 NO FONT SIMM FOR PAGES, ESC/P on page 126

Chapter 1. Getting Started 32

Print Quality Problems


The quality of the printed image depends upon many factors, some controlled by the customer and some by service. The following customer controlled items should be as described in the IBM InfoPrint 20: Users Guide: v Toner v Paper, envelopes, or transparencies v Consumable supplies replenished at the correct intervals v Stable operating environment Temperature Humidity v Location On a level surface Proper ventilation Shielded from direct rays from the sun Low dust content Not near water outlets, steamers, electric heaters, volatile gases, or open ame v Supplies Storage at the warehouse Storage in the printer operating environment Service should perform the following: v Replace worn parts v Check printer performance and print quality at every visit.

Chapter 1. Getting Started 33

Print Quality Defects


Before analyzing print quality (PQ) problems, verify that no supply item, such as the EP cartridge, needs replacing. Also, check the items listed under Print Quality Problems on page 33. From Table 8, select the Problem , and then Go To ... the suggested procedure to isolate the failure.
Table 8. Print Quality Diagnostics Quick Path
Problem Background Black Horizontal Stripes Black Prints Blank Prints Damaged Print Fusing Light (Undertoned) Prints Residual Image Skewed Image Spots Streaks, Horizontal Streaks, Vertical Unusual Patterns Voids Voids, Horizontal Band Voids, Vertical Band Background on page 184 Black Horizontal Stripes on page 195 Black Prints on page 188 Blank Prints on page 191 Damaged Print on page 196 Fusing, Not Fused or Partially Fused Image on page 200 Light (Undertoned) Prints on page 203 Residual Image on page 208 Skewed Image on page 212 Spots on page 216 Streaks, Horizontal on page 219 Streaks, Vertical on page 223 Unusual Patterns on page 227 Voids on page 229 Voids, Horizontal on page 232 Voids, Vertical on page 236 Go To...

Chapter 1. Getting Started 34

Miscellaneous, Routine Tasks


This section guides you to performing routine printer tasks. When the tasks are completed, go to Completing Service on page 36. From Table 9, select the Task , and then Go To ... the suggested procedure.
Table 9. Routine Tasks
Task Cleaners Conguration page, running Error log, using Installing the printer Locating assemblies and parts Lubricants Power-Receptacle Safety-Check Relocating the printer Replenishing supplies Run test prints Safety Inspection 200K usage kit Go To... Cleaners and Lubricants on page 588 Conguration Page on page 250 Error Log on page 254 IBM InfoPrint 20: Users Guide Chapter 5. Locations on page 360 Cleaners and Lubricants on page 588 Power-Receptacle Safety-Check on page 17 IBM InfoPrint 20: Users Guide IBM InfoPrint 20: Users Guide Test Prints on page 251 Safety Inspection on page 12 Chapter 7. Preventive Maintenance and Usage Kit on page 543

Chapter 1. Getting Started 35

Completing Service
Note: If you replaced a part that did not correct the problem, reinstall the original part. If the printer has not been xed using the procedures that you were directed to perform, return to Diagnostic Quick Path on page 28. Ensure that you have correctly interpreted the available information, and then dene the problem again. If a solution is not found, call your next level of support (see Appendix D. Technical Support on page 602). Use the following as a guide to ensure high quality printer operation: 1. Ensure the following: a. All internal cables and connectors are correctly connected. b. All covers, doors, panels, and trays are in place. c. Any workstation or network cable is connected. d. All power cords are connected. 2. Switch on printer power and ensure the following: a. IBM INFOPRINT 20 displays. b. WARMING UP displays. c. READY displays within approximately 2-minutes or the printer begins printing if a job is in the print queue. 3. Run test prints from the operator panel to ensure high quality output. Show these to the operator. 4. Have the operator run a print job. 5. Clean the work area. 6. Clean the printer covers with a dry cleaning cloth; if necessary, use water and a mild detergent (non-ammonia). 7. Return control of the printer to the operator.

Chapter 1. Getting Started 36

Chapter 2. Diagnosing Problems


General Information . . . . . . . . . . . . . . Using Diagnostic Tables . . . . . . . . . . . . Diagnostics . . . . . . . . . . . . . . . . . . Error Codes with Messages . . . . . . . . . 02 TONER LOW . . . . . . . . . . . . . . 03 2000 SHEET INPUT COVER OPEN . . 04 TONER CART MISSING . . . . . . . . 06 TOP COVER OPEN . . . . . . . . . . 09 DUPLEX COVER OPEN . . . . . . . . 10 FUSER COVER OPEN. . . . . . . . . 11 LOAD <size> IN <source> . . . . . . . 12 MANUALLY LOAD paper_size IN AUX . 14 ADJUST PAPER GUIDES IN TRAY n . 15 2000 SHEET INPUT NOT READY . . . 16 TRAY n MISSING . . . . . . . . . . . 17 TRAY OPTION ERROR . . . . . . . . 17 2000 SHEET INPUT ERROR . . . . . 20 PAPER JAM . . . . . . . . . . . . . . 21 PAPER JAM . . . . . . . . . . . . . . 22 PAPER JAM . . . . . . . . . . . . . . 23 PAPER JAM . . . . . . . . . . . . . . 24 PAPER JAM . . . . . . . . . . . . . . 26 PAPER JAM . . . . . . . . . . . . . . 27 PAPER ERROR <source> . . . . . . . 29 OUTPUT FULL . . . . . . . . . . . . . 30 MEMORY OVERFLOW . . . . . . . . 31 MEMORY ALLOC ERROR . . . . . . .
Copyright IBM Corp. 1998

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. 41 . 43 . 44 . 45 . 46 . 49 . 50 . 52 . 54 . 55 . 58 . 64 . 64 . 64 . 65 . 68 . 68 . 69 . 73 . 83 . 84 . 89 . 94 . 94 . 98 .101 .101 37

32 PRINT OVERRUN . . . . . . . . . . . 40 MEMORY OPTION ERROR . . . . . . 41 NETWORK OPTION ERROR . . . . . 42 NETWORK OPTION ERROR . . . . . 43 PS OPTION ERROR . . . . . . . . . . 44 IPDS OPTION ERROR. . . . . . . . . 45 OPTION ERROR . . . . . . . . . . . . 46 NETWORK OPTION ERROR . . . . . 50 ERROR CALL FOR SERVICE . . . . . 51 ERROR CALL FOR SERVICE . . . . . 52 ERROR CALL FOR SERVICE . . . . . 53 ERROR CALL FOR SERVICE . . . . . 54 ERROR CALL FOR SERVICE . . . . . 55 ERROR CALL FOR SERVICE . . . . . 56 ERROR CALL FOR SERVICE . . . . . 61 ERROR CALL FOR SERVICE . . . . . 62 ERROR CALL FOR SERVICE . . . . . 63 ERROR CALL FOR SERVICE . . . . . 71 DISK ERROR . . . . . . . . . . . . . 72 DISK ERROR . . . . . . . . . . . . . 73 DISK ERROR . . . . . . . . . . . . . 80 ADD MEMORY FOR IPDS . . . . . . . 80 ADD MEMORY FOR PAGES, ESC/P . 81 INSUFFICIENT MEMORY FOR IPDS . 81 INSUFFICIENT MEMORY FOR PAGES 82 HOST TIMEOUT . . . . . . . . . . . . 83 CX SEND STATE. . . . . . . . . . . . 84 NO FONT SIMM FOR PAGES, ESC/P . Printer Problems without Error Codes . . . . Fuse or Power Problem . . . . . . . . . .

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.101 .101 .102 .102 .103 .103 .104 .104 .105 .108 .109 .114 .119 .120 .122 .123 .123 .124 .124 .124 .125 .125 .125 .125 .125 .126 .126 .126 .127 .127

Chapter 2. Diagnosing Problems 38

Intermittent or Random Problems . . . . . . . . Operator Panel, Controller, and Power Problems Toner Low and No Error Code 02 Displayed . . Other Diagnostics . . . . . . . . . . . . . . . . . 24V Power Supply to MCU . . . . . . . . . . . Electrical Noise . . . . . . . . . . . . . . . . . Ethernet / Token-Ring NIC Printing Problems . . Feed Solenoid . . . . . . . . . . . . . . . . . . HVPS . . . . . . . . . . . . . . . . . . . . . . LVPS. . . . . . . . . . . . . . . . . . . . . . . Paper Size Switch - 500-Sheet Paper Trays. . . Pick Up Solenoid (Auxiliary Tray) . . . . . . . . Registration Sensor . . . . . . . . . . . . . . . Toner Sensor . . . . . . . . . . . . . . . . . . Twinax / Coax NIC Printing Problems . . . . . . Print Quality . . . . . . . . . . . . . . . . . . . . Background . . . . . . . . . . . . . . . . . . . Black Prints . . . . . . . . . . . . . . . . . . . Blank Prints . . . . . . . . . . . . . . . . . . . Black Horizontal Stripes . . . . . . . . . . . . . Damaged Print. . . . . . . . . . . . . . . . . . Fusing, Not Fused or Partially Fused Image. . . Light (Undertoned) Prints . . . . . . . . . . . . Residual Image . . . . . . . . . . . . . . . . . Skewed Image . . . . . . . . . . . . . . . . . . Spots . . . . . . . . . . . . . . . . . . . . . . Streaks, Horizontal. . . . . . . . . . . . . . . . Streaks, Vertical . . . . . . . . . . . . . . . . . Unusual Patterns . . . . . . . . . . . . . . . . Voids. . . . . . . . . . . . . . . . . . . . . . .

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.133 .135 .142 .144 .144 .146 .150 .155 .159 .163 .165 .170 .172 .176 .179 .184 .184 .188 .191 .195 .196 .200 .203 .208 .212 .216 .219 .223 .227 .229

Chapter 2. Diagnosing Problems 39

Voids, Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232 Voids, Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236 Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Chapter 2. Diagnosing Problems 40

General Information
The Diagnostic Quick Path should have directed you to this section to analyze your printer problem. 1. Diagnostics assume there are no code problems in the printer controller. If you are unable to x a problem using the diagnostics, we recommend that you replace the printer controller and obtain the latest level code. 2. Diagnostics frequently use new or known good components as diagnostic tools. We recommend you carry a spare Toner Cartridge (EP Cartridge), MCU PWB, Printer Controller PWB, and Power Supply PWB. 3. Unless indicated otherwise, the instruction switch ON main power means for you to SWITCH ON printer power and let the printer proceed through power-on diagnostics and warm-up until it is on-line and ready to print. 4. Unless indicated otherwise, you should inspect and conrm the status of those components listed under the title of SUSPECT COMPONENTS at the rst part of each diagnostic. The inspection items are: v Installed properly? v Not damaged or deformed? v Not contaminated with foreign material? 5. If you cannot isolate the problem using the diagnostics, replace each component listed under the title of SUSPECT COMPONENTS at the rst part of each diagnostic, one at a time, until the problem is xed. 6. Conventions used to represent connectors, v P/J XX means that the Plug and its corresponding Jack are connected. v PXX means that the Plug is disconnected. (Unless this plug is soldered to a PWB). v JXX means that the Jack is disconnected. (Unless this jack is soldered to PWB). 7. When you are instructed to take a voltage reading between P/J A-B and P/J X-Y, place the red probe (+) of your meter on pin B of P/J A, and place the black probe (-) of your meter on pin Y of P/J X. 8. When you are instructed to take a voltage reading between P/J X and P/J Y (without specied pin numbers), check all voltage carrying pins. See the Wiring Diagrams for signals and pin numbers.
Chapter 2. Diagnosing Problems 41

9. Plug numbers are indicated on the circuit board. In there are 8 pins in a plug, you can nd a 1 (or A) at one end and an 8 or (H) at the other end. The other pins, such as 6, are found by counting from one end. 10. When you are instructed to take a voltage reading, the black probe (-) is generally connected to a pin that is either RTN (Return) or FG (Frame Ground) in place of any SG pin or test point. 11. Unless an diagnostic instructs you otherwise, before measuring voltages make sure the printer is switched ON, the Print Cartridge and the Paper Cassette are installed, and the Exit Cover is closed (Interlock Switch is actuated). 12. All voltage values given in the diagnostics are approximate. Measured voltages may vary more than 25% from the values stated in the diagnostics. The main purpose of most voltage readings taken in the diagnostics is to determine whether or not a component is receiving the correct high voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on a multimeter. 13. Diagnostics may instruct you to remove or replace a component. See Chapter 6. Removal Procedures, Adjustments on page 394 for information on how to remove and reinstall a component. 14. When a diagnostic instructs you to replace a component and that component is part of a larger assembly, you should replace the entire assembly.

Chapter 2. Diagnosing Problems 42

Using Diagnostic Tables


1. 2. 3. 4. 5. 6. Each numbered step in a diagnostic instructs you to perform a certain action or procedure. The action box may contain additional information and numbered substeps to perform the action. The action is followed by a question. If your response to the question is Yes, follow the instructions for a Yes reply. If your response to the question is No, follow the instructions for a No reply. Diagnostics often ask you to take voltage readings at certain test points. Chapter 4. Circuit Diagrams on page 307 and Chapter 5. Locations on page 360 contain information on test point locations and signal names.

7. Diagnostics often ask you to replace a printer component. Chapter 6. Removal Procedures, Adjustments on page 394 provides detailed steps for removing and replacing all major parts of the printer.

Chapter 2. Diagnosing Problems 43

Diagnostics
Diagnostic Quick Path on page 28 is the entry point for all problems. If at any point the diagnostic to which you have been directed does not solve the problem, return to the Diagnostic Quick Path. Diagnostics are listed as follows: 1. Error Codes with Messages on page 45 Error codes with messages are described here. 2. Printer Problems without Error Codes on page 127 You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post an error code. 3. Other Diagnostics on page 144 These are secondary diagnostics pointed to by other diagnostics. 4. Print Quality on page 184 Each of these diagnostics has an illustration of the print quality symptom discussed in the diagnostic.

Chapter 2. Diagnosing Problems 44

Error Codes with Messages


Error codes (listed numerically) with messages are described here.

Chapter 2. Diagnosing Problems 45

02 TONER LOW
Meaning: The EP Cartridge is nearing end-of-life and should be replaced. This error can also occur if the EP Cartridge is misaligned, caused by the side guides or BTR assembly. Action: Press the Continue key to continue printing (the TONER LOW message remains on the display). Ensure that a new EP cartridge is available. When the print quality becomes unacceptable, install a new EP cartridge. The TONER LOW item on the Paper Menu lets you specify whether or not you want the printer to stop printing when it detects a TONER LOW condition. If toner is low and error code 02 does not display, go to Toner Low and No Error Code 02 Displayed on page 142. If this action does not x the problem, go to Table 10.
Table 10. 02 TONER LOW
Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v Toner Relay Harness (Asm-Index: 12-18, page 575) v MSI Bracket Assembly (Asm-Index: 5-7, page 557) v MCU PWB (Asm-Index: 12-8, page 575) EP CARTRIDGE 1. Install a new EP Cartridge. Does the Error Code 02 TONER LOW still appear? Go to step 2 Verify the x. Also verify that the problem job prints. Yes No

Chapter 2. Diagnosing Problems 46

Table 10. 02 TONER LOW (continued)


Step Actions and Questions Yes No Go to step 3

2.

FUNCTION OF TONER SENSOR Replace the a. Use D21 SENSOR TEST on page 261 to check the function of the Toner MCU, or there is an EP cartridge Sensor Assembly. alignment Note: The Pop Up Unit must be closed in the next step. problem. b. Depress the switch with a non-magnetized piece of steel. Does the Toner Sensor function correctly?

3.

TONER SENSOR CONNECTION Is the Toner Sensor connection (P/J221) OK? TONER SENSOR ASSEMBLY (Asm-Index: 5-13, page 557)

Go to step 4

Repair as needed

4.

Install a new Toner Sensor Assembly (See page 462). Is the problem xed? TONER RELAY HARNESS

Verify the x. Also Go to step 5 verify that the problem job prints. Go to step 6 Repair as needed

5.

Inspect the Toner Relay Harness (P/J22 at the MCU; P/J222 at the Toner Sensor Harness). Is the harness OK? MSI BRACKET ASSEMBLY (Asm-Index: 5-7, page 557)

6.

Replace the MSI Bracket Assembly (See page 457). Is the problem xed?

Verify the x. Also Go to the last verify that the step of this problem job diagnostic. prints.

Chapter 2. Diagnosing Problems 47

Table 10. 02 TONER LOW (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

7.

Chapter 2. Diagnosing Problems 48

03 2000 SHEET INPUT COVER OPEN


Meaning: The cover at the back of the 2000-Sheet Input Drawer is open. Action: Close the cover. If the message persists, make sure both corners of the cover are completely closed. Also check for paper inside the cover. Error Code Diagnostic Procedure: 03 2000-SHEET COVER OPEN on page 708.

Chapter 2. Diagnosing Problems 49

04 TONER CART MISSING


Meaning: The EP Cartridge is not in place or is installed incorrectly. Action: Open the printer and make sure the EP cartridge is seated correctly. If you have not installed a EP cartridge, do so now. If this action does not x the problem, go to Table 11.
Table 11. 04 TONER CART MISSING
Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v CRU Sensor Assembly (Asm-Index: 11-15, page 572), includes cable v MCU PWB (Asm-Index: 12-8, page 575) Install a new EP Cartridge. 1. Does the LCD display a 04 TONER CART MISSING? CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572) 2. Press and release the CRU Sensor Assembly. Does the CRU Sensor Assembly lever move smoothly? FUNCTION OF CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572) 3. Possible Go to step 4 intermittent or a. Use D21 SENSOR TEST on page 261 to check the function of the CRU random problems Sensor Assembly. (See page 133) b. Actuate the CRU Sensor Assembly. Does the CRU Sensor function correctly? Go to step 3 Go to step 2 Verify the x. Also verify that the problem job prints. Replace the CRU Sensor Assembly (See page 503) Yes No

Chapter 2. Diagnosing Problems 50

Table 11. 04 TONER CART MISSING (continued)


Step 4. Actions and Questions CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572) Replace the CRU Sensor Assembly (See page 503). Is the problem xed? 5. FRAME ALIGNMENT When you close the top cover, is the CRU Sensor activated? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

Verify the x. Also Go to step 5 verify that the problem job prints. Replace the MCU Repair as needed PWB (See page 526 or 529)

6.

Chapter 2. Diagnosing Problems 51

06 TOP COVER OPEN


Meaning: The top cover is open. Action: Close the cover. If this action does not x the problem, go to Table 12.
Table 12. 06 TOP COVER OPEN
Step Actions and Questions SUSPECT COMPONENTS v Interlock Switch (Asm-Index: 12-1, page 575) v Interlock Actuator (Asm-Index: 11-19, page 572) v ROS Support (Asm-Index: 11-18, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) INTERLOCK SWITCH (Asm-Index: 12-1, page 575) and INTERLOCK ACTUATOR (Asm-Index: 11-19, page 572) 1. a. Open and close the Pop Up Unit. b. Inspect the movement of the Interlock Switch. Does the actuator tab press down on the Interlock Switch lever? FUNCTION OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575) 2. a. Use D21 SENSOR TEST on page 261 to check the Interlock Switch. b. Open and close the Pop Up Unit. Does the Interlock Switch function correctly? Possible Go to step 3 intermittent or random problems (See page 133) Go to step 2 Replace the Interlock Actuator or the Interlock Switch (See page 513) Yes No

Chapter 2. Diagnosing Problems 52

Table 12. 06 TOP COVER OPEN (continued)


Step Actions and Questions CONTINUITY OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575) a. Remove the Controller Assembly (See page 535). 3. b. Disconnect P/J21 and P/J123. c. Press and release the Interlock Switch. d. Check for the continuity between J21-1 <=> J123-1. Is there continuity between J21-1 <=> J123-1 when you press the Interlock Switch and no continuity when you release it? LVPS ASSEMBLY (Asm-Index: 12-4, page 575) a. Reconnect P/J21 from the MCU PWB and P/J123 from the LVPS Assembly. b. Open and Close the Pop Up Unit. c. Measure the voltage between P/J21-1 <=> P/J11-1. Is the voltage between P/J21-1 <=> P/J11-1 24VDC when you close the Pop Up Cover Assembly, and 0VDC when you open it? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Replace the MCU Verify that the PWB (See page cover activates 526 or 529) the sensor correctly, then replace the LVPS Assembly (See page 521) Yes Go to step 4 No Replace the Interlock Switch (See page 513)

4.

5.

Chapter 2. Diagnosing Problems 53

09 DUPLEX COVER OPEN


Meaning: A cover on the duplex unit is open. Action: Make sure both duplex covers are closed. Error Code Diagnostic Procedure: 09 DUPLEX COVER OPEN on page 607.

Chapter 2. Diagnosing Problems 54

10 FUSER COVER OPEN


Meaning: The Fuser Cover (the Main Interlock Switch) is open. Action: Close the cover. If this action does not x the problem, go to Table 13.
Table 13. 10 FUSER COVER OPEN
Step Actions and Questions SUSPECT COMPONENTS v Duplex Interface PWB (Asm-Index: 12-6, page 575) or its MCU connection Note: The Duplex Interface PWB can appear to be seated when it is not. v Fuser Cover Switch (Asm-Index: 12-2, page 575) v Fuser Cover Assembly (Asm-Index: 1-1, page 548) v MCU PWB (Asm-Index: 12-8, page 575) v Fuser Switch Cover Harness (Asm-Index: 12-13, page 575) FUSER COVER SWITCH (Asm-Index: 2-2, page 550) a. Open and close the Fuser Cover Assembly (Asm-Index: 1-1, page 548). 1. b. Inspect the contact of the Fuser Cover with the Fuser Cover Switch (Asm-Index: 12-2, page 575). c. Ensure the switch is installed properly and the bracket is not bent. d. Push and release the Fuser Cover Switch manually. Does the Fuser Cover Assembly actuate the Fuser Cover Switch, and does the Fuser Cover Switch move smoothly? Go to step 2 Replace the Fuser Cover Assembly (See page 400) or the Fuser Cover Switch (See page 516) Yes No

Chapter 2. Diagnosing Problems 55

Table 13. 10 FUSER COVER OPEN (continued)


Step Actions and Questions CONTINUITY OF FUSER COVER SWITCH (Asm-Index: 12-2, page 575) a. Open the Fuser Cover (Asm-Index: 1-2, page 548). b. Remove the Fuser Cover Switch (See page 516). 2. c. Unplug P/J190 from the Fuser Cover Switch (See page 516). d. Press and release the actuator of the Fuser Cover Switch. e. Check continuity from 1A to 1B, and 2A to 2B on the Fuser Cover Switch (the pins are labeled in the plastic on the bottom of the switch). Is there continuity on the pair of switch pins when you press the actuator and no continuity when you release it? DUPLEX INTERFACE PWB (Asm-Index: 12-6, page 575) a. Remove the Controller Assembly (See page 535). b. Find the Duplex Interface PWB. It is the small board that bridges the duplex option connector (above the power connector) to the MCU PWB (P/J18). c. Ensure that the connector between the MCU PWB (P/J18) and the Duplex Interface PWB is properly seated. Note: The Duplex Interface PWB can appear to be seated when it is not. Is the Duplex Interface PWB properly seated? 4. The Fuser Cover harness connects to the Duplex Interface PWB at P/J180. Go to step 5 This connector is located on the top on the Duplex Interface PWB. P/J180 can be easily damaged. Is P/J180 OK? Replace the Duplex Interface PWB (See page 524). Go to step 4 Reconnect P/J18. Verify the x. Also verify that the problem job prints. Yes Go to step 3 No Replace the Fuser Cover Switch (See page 516)

3.

Chapter 2. Diagnosing Problems 56

Table 13. 10 FUSER COVER OPEN (continued)


Step Actions and Questions One of the following parts is bad: v Duplex Interface PWB (Asm-Index: 12-6, page 575) 5. v Fuser Cover Harness (Asm-Index: 12-13, page 575) v MCU PWB (Asm-Index: 12-8, page 575) Yes No

6.

End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

Chapter 2. Diagnosing Problems 57

11 LOAD <size> IN <source>


Meaning: The tray is out of paper, the tray contains the wrong size paper, or the tray is loaded incorrectly. The message identies the size of paper (size) and the tray (source) that needs paper. If the message indicates a tray you do not think you specied, automatic tray switching may be enabled. This error can occur if paper empty or size sensing is bad in any paper source. Actions: v If the tray is empty, ll it. The printer will resume printing. v If the tray contains the wrong size paper, you have two choices: to use the current paper size, press the Continue key; otherwise, load the correct paper size into the tray. v If the tray contains the right size paper, make sure the paper is loaded correctly. Check the paper guides. The AUTOSENSED PAPER section of the printer conguration page shows what size paper the printer paper size sensors have determined is in each tray. v If the tray is empty, rell it. The printer will resume printing. v If you are printing a printer conguration page, make sure Letter or A4 size paper is loaded in the default tray.

Chapter 2. Diagnosing Problems 58

Table 14. 11 LOAD <size> IN <source>


Step Actions and Questions SUSPECT COMPONENTS v Problems only from Auxiliary Tray: PAPER MENU/AUXSIZE setting wrong MSI No Paper Sensor (Asm-Index: 5-9, page 557), includes harness MSI No Paper Actuator (Asm-Index: 5-10, page 557) v Tray empty problems only from Tray 1: Cassette No Paper Sensor (Asm-Index: 3-11, page 553) Cassette No Paper Actuator (Asm-Index: 3-16, page 553) Feeder Harness (Asm-Index: 3-12, page 553) v Tray size problems with Tray 1 and possibly Tray 2 or 3 v Feeder PWB (Asm-Index: 3-1, page 553) v Tray Harness (Asm-Index: 12-17, page 575) v Problems only with one Optional Tray: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) 2000-Sheet Input Option: Analyze using Appendix H. 2000-Sheet Input Drawer Option on page 703 v General: MCU PWB (Asm-Index: 12-8, page 575) Yes No

Chapter 2. Diagnosing Problems 59

Table 14. 11 LOAD <size> IN <source> (continued)


Step Actions and Questions TRAY EMPTY SENSING a. During the next steps, record which sources print OK and which sources are involved with the problem. Clear jams (open and close the top cover) as necessary. Note that CONFIG PAGES will try a reprint after the jam is cleared you can press ONLINE to cancel. b. Set PAPER MENU/TRAYSWITCH=OFF. Note: Tray switching may affect behavior with real jobs. CONFIG pages will try to print only on Letter or A4 paper that is loaded. c. Load Tray 1 (the standard 500 sheet input) with letter or A4 paper (empty all other paper sources). Set the PAPER MENU/SOURCE=TRAY 1. Try to print using TEST MENU/CONFIG PAGE. If a jam occurs, clear it. d. Load the Auxiliary Tray (the ip-down MSI input at the front of the printer). Ensure that PAPER MENU/ AUXSIZE matches the loaded paper size/orientation. Set PAPER MENU/SOURCE=AUX. Try to print another CONFIG PAGE. e. If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeat the above steps for Tray 2. f. If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat the above steps for Tray 3. Did the 11 LOAD <size> IN <source> ever occur? Does the problem appear when using Tray 2 or 3? Go to 11 LOAD Go to step 3 <size> IN TRAY n on page 663. Or analyze using Appendix H. 2000-Sheet Input Drawer Option on page 703. Yes Look at a CONFIG page from another source. Verify that the loaded paper matches AUTOSENSED PAPER details. If not, go to Paper Size Switch 500-Sheet Paper Trays on page 165. If AUTOSENSED PAPER is OK, go to step 2. No For other messages or symptoms, go to Chapter 1. Getting Started on page 25. If there is no message, the user may be sending jobs with a size/source mismatch.

1.

2.

Chapter 2. Diagnosing Problems 60

Table 14. 11 LOAD <size> IN <source> (continued)


Step 3. Actions and Questions Does the 11 LOAD <size> IN <source> error code appear when you feed paper from Auxiliary Tray (MSI)? MSI NO PAPER ACTUATOR (Asm-Index: 5-10, page 557) 4. Insert then remove a piece of paper into the Multi Sheet Inserter. Do the MSI No Paper Actuator move smoothly when paper is inserted then removed? MSI NO PAPER SENSOR a. Use D21 SENSOR TEST on page 261 to check the MSI No Paper Sensor (Asm-Index: 5-9, page 557). b. Press and then release the MSI No Paper Actuator. Does the MSI No Paper Sensor work correctly? Replace the following: v MSI Bracket Assembly (See page 457) v MSI No Paper Sensor (See page 460) Is the problem xed? The MSI no paper sensing problem could be caused by one of the following: v MCU PWB (Asm-Index: 12-8, page 575) 7. v High Harness Assembly (Asm-Index: 6-5, page 559) v LVPS Assembly (Asm-Index: 12-4, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) Verify the x. Also Go to step 7 verify that the problem job prints. Yes Go to step 4 No Go to step 8

Go to step 5

Repair or replace the MSI No Paper Actuator (See page 460)

5.

Go to step 8. Go to step 6 Possible intermittent or random problems (See page 133)

6.

Chapter 2. Diagnosing Problems 61

Table 14. 11 LOAD <size> IN <source> (continued)


Step Actions and Questions PAPER CASSETTE (Asm: 2, page 550) There is problem with Tray 1 no paper sensing. 8. a. Remove the Paper Cassette from the printer. b. Remove the Cassette Cover (Asm-Index: 2-25, page 550) and all paper from the Paper Cassette. c. Insert the Paper Cassette into the printer and inspect the Bottom Plate Assembly (Asm-Index: 2-10, page 550). Is the Bottom Plate Assembly raised? CASSETTE NO PAPER ACTUATOR (Asm-Index: 3-16, page 553) 9. Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553). Does the Cassette No Paper Actuator move smoothly? CASSETTE NO-PAPER SENSOR (Asm-Index: 3-11, page 553) a. Use D21 SENSOR TEST on page 261 to check the Cassette No Paper Sensor. b. Release the tray 1 Low Paper Actuator (Asm-Index: 3-10, page 553) c. Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553). Does the Cassette No Paper Sensor function correctly? CASSETTE NO PAPER SENSOR (Asm-Index: 3-11, page 553) 11. Replace the Cassette No Paper Sensor (See page 430). Is the problem xed? Verify the x. Also Go to step 12 verify that the problem job prints. Go to step 10 Replace the Cassette No Paper Actuator (See page 436) Yes Go to step 9 No Replace the Paper Cassette

10.

Possible Go to step 11 intermittent or random problems (See page 133)

Chapter 2. Diagnosing Problems 62

Table 14. 11 LOAD <size> IN <source> (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

12.

Chapter 2. Diagnosing Problems 63

12 MANUALLY LOAD paper_size IN AUX


Meaning: The auxiliary tray requires paper. The message indicates the required size (paper_size). Action: Place another sheet of paper or other media in the auxiliary tray and press the Continue key. If you receive this message and you do not want the manual printing function, set MANUAL to OFF on the Paper Menu or using your printer driver.

14 ADJUST PAPER GUIDES IN TRAY n


Meaning: Paper guides in the specied tray need adjusting. Action: Adjust the paper guides.

15 2000 SHEET INPUT NOT READY


Meaning: The elevator mechanism in the 2000-Sheet Input Drawer is moving or out of position. Action: Wait for the elevator to stop moving. Make sure the 2000-Sheet Input Drawer is in place. Error Code Diagnostic Procedure: 15 TRAY n NOT READY on page 709.

Chapter 2. Diagnosing Problems 64

16 TRAY n MISSING
Meaning: Paper Cassette (Tray 1), Tray 2 or Tray 3 are not in place. Action: Open and close the tray. If you have not installed the tray, do so at this time. If this action does not x the problem, go to Table 15.
Table 15. 16 TRAY n MISSING
Step Actions and Questions SUSPECT COMPONENTS v Tray 1 Problems: Feeder PWB (Asm-Index: 3-1, page 553) Cassette Guide L (Asm-Index: 3-7, page 553) Paper Cassette (Asm: 2, page 550) v Tray 2 Problems: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) v Tray Harness (Asm-Index: 12-17, page 575) v General: MCU PWB (Asm-Index: 12-8, page 575) Does the Error Code specify Tray 2 or Tray 3? 1. Go to Appendix G. 500-Sheet Paper Tray Option on page 661 Go to step 2 Yes No

Chapter 2. Diagnosing Problems 65

Table 15. 16 TRAY n MISSING (continued)


Step 2. Actions and Questions Remove and reinstall the affected paper cassette (Asm: 2, page 550). Does the 16 TRAY n MISSING error code still appear? PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS 3. Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page 553). Note: If the switches are activated, answer No to the following question. Do the Size Cam states match the loaded paper size? (see Paper Size Switch - 500-Sheet Paper Trays on page 165) PAPER SIZE CAM (Asm-Index: 2-20, page 550) MECHANICS Inspect the suspect components and their settings relating to the Size Cam as: v End Guide Plate (Asm-Index: 2-14, page 550) v Paper End Guide (Asm-Index: 2-15, page 550) 4. v End Guide Spring (Asm-Index: 2-16, page 550) v End Guide (Asm-Index: 2-17, page 550) v Pivot Plate (Asm-Index: 2-18, page 550) v Sector Gear (Asm-Index: 2-19, page 550) v Size Cam Is there any damage or wrong setting on those suspect components? Replace damaged Go to step 6 parts, adjust setting, or install a new cassette Go to step 5 Yes Go to step 3 No Verify the x. Also verify that the problem job prints. Go to step 4

Chapter 2. Diagnosing Problems 66

Table 15. 16 TRAY n MISSING (continued)


Step Actions and Questions PAPER SIZE SWITCH a. Remove the Paper Cassette (Asm: 2, page 550). 5. Yes No

Replace the MCU Go to Paper Size PWB (See page Switch 526 or 529) 500-Sheet Paper b. Use D21 SENSOR TEST on page 261 to check the function of the Paper Trays on Size Switch. page 165 c. Reach inside the paper feeder and press and release each Size Actuator (Asm-Index: 3-8, page 553), one Actuator at a time, pressing ENTER between each Actuator tested. Do the Size Switches function correctly? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

6.

Chapter 2. Diagnosing Problems 67

17 TRAY OPTION ERROR


Meaning: An optional paper tray was detected previously, but is no longer detected. Action: Make sure that the tray is installed correctly. Error Code Diagnostic Procedure: 17 TRAY n OPTION ERROR on page 664.

17 2000 SHEET INPUT ERROR


Meaning: The 2000-Sheet Input Drawer is not ready. Action: Make sure that the 2000-Sheet Input Drawer has power and is properly installed. Error Code Diagnostic Procedure: 17 2000 SHEET INPUT ERROR on page 710.

Chapter 2. Diagnosing Problems 68

20 PAPER JAM
Meaning: There is a paper jam at the Exit Sensor (Exit Photo Sensor). Action: Remove jammed paper from the paper path. Open and close the top cover. If this action does not x the problem, go to Table 16.
Table 16. 20 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor v Duplex Unit (Asm: 30, page 652) v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v Exit Cover (Asm-Index: 1-12, page 548) 1. PAPER CONDITIONS Is the paper wrinkled, damaged, or damp? 2. Switch ON main power. Is 20 PAPER JAM displayed when you Switch ON power? PAPER AT EXIT ACTUATOR (Asm-Index: 8-24, page 564) 3. a. Open the Fuser Cover. b. Open the Fuser Access Cover. Is there paper at the Exit Actuator inside the Fuser? Remove the Go to step 10 paper. Go to step 4. Replace with fresh, dry paper Go to step 3 Go to step 2 Yes No

Go to step 5

Chapter 2. Diagnosing Problems 69

Table 16. 20 PAPER JAM (continued)


Step 4. Actions and Questions Is the Error Code 20 PAPER JAM gone? Yes No

Verify the x. Also Go to step 5 verify that the problem job prints. Ensure that the Go to step 6 Duplex Unit is installed correctly and plugged into the duplex connection. If it is, go to Appendix E. Duplex Unit Option on page 604. Replace the Fuser Assembly (See page 487)

DUPLEX UNIT (Asm-Index: 30-1, page 652) Does the problem appear using the Duplex Unit? 5.

CAUTION: Go to step 7 <2-35> Remove all watches, rings, jewelry, and other articles (such as a necktie) that may catch on printer parts before working in this area. ROTATION OF EXIT ROLL ASSEMBLY (Asm-Index: 9-31, page 567) 6. a. Switch ON main power. b. Inspect the rotation of the Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly (Asm-Index: 8-6, page 564) during the warm up period. Does the Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly rotate smoothly?

Chapter 2. Diagnosing Problems 70

Table 16. 20 PAPER JAM (continued)


Step Actions and Questions EXIT ROLL ASSEMBLY (Asm-Index: 9-31, page 567) 7. a. Run a Test Print. b. Inspect the paper path through Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly (Asm-Index: 8-6, page 564). Does the paper pass through the Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly? PAPER CASSETTE 8. Does Error Code 20 PAPER JAM appear only when using the Paper Cassette? EXIT ACTUATOR (Asm-Index: 8-24, page 564) a. Remove the Exit Cover (See page 414). b. Open the Fuser Cover (Asm-Index: 1-2, page 548) and the Fuser Rear Cover (Asm-Index: 8-11, page 564). c. Actuate and release the Exit Actuator. d. Inspect the position of the lever. Is the arm of the Exit Actuator away from the detecting points of the Exit Sensor when you actuate the Actuator, and does the arm shield the detecting points when you release it? EXIT SENSOR (Asm-Index: 8-25, page 564) 10. Bad MCU PWB Go to step 11 (See page 526 or Use D21 SENSOR TEST on page 261 to check the Exit Sensor function (you 529), or possible will need to override the fuser cover switch). intermittent or random problems Does the Exit Sensor function correctly? (See page 133) Go to 27 PAPER Go to step 9 ERROR <source> on page 94 Go to step 10 Replace the Fuser Assembly (See page 487) Yes Go to step 8 No Replace the Fuser Assembly (See page 487)

9.

Chapter 2. Diagnosing Problems 71

Table 16. 20 PAPER JAM (continued)


Step Actions and Questions FUSER ASSEMBLY (Asm-Index: 8-1, page 564) 11. Replace the Fuser Assembly (See page 487). Note: The Fuser is part of the Usage Kit. Is the problem xed? The Fuser exit sensing is bad, one of the following parts is bad: v High Harness Assembly (Asm-Index: 6-5, page 559) 12. v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

Verify the x. Also Go to step 12 verify that the problem job prints.

13.

Chapter 2. Diagnosing Problems 72

21 PAPER JAM
Meaning: Misfeed jam. There is a paper jam between the paper inputs (Tray 1, 2, 3, AUX Tray) and the Registration Sensor. Action: Remove jammed paper from the paper path. Make sure paper is loaded correctly. Open and close the top cover. Note: If the 21 PAPER JAM error occurs only when paper re-enters the printer from the duplex option, go to 22 PAPER JAM (or 21 PAPER JAM from Duplex) on page 608. SUSPECT COMPONENTS v Jams only from Auxiliary Tray: Transport Chute Assembly (Asm-Index: 6-2, page 559) MSI No Paper Sensor (Asm-Index: 5-9, page 557) MSI No Paper Actuator (Asm-Index: 5-10, page 557) Pick Up Solenoid (Asm-Index: 6-17, page 559) Pick Up Roll (Asm-Index: 6-9, page 559) Retard Pad Assembly (Asm-Index: 6-18, page 559) Front Bottom Tray (Asm-Index: 5-5, page 557) v Jams only from Tray 1: Cassette No Paper Sensor (Asm-Index: 3-11, page 553) Cassette No Paper Actuator (Asm-Index: 3-16, page 553) Feed Solenoid (Asm-Index: 4-8, page 555) Feed Roll (Asm-Index: 4-1, page 555) Feeder Harness (Asm-Index: 3-12, page 553). Use P/N 90H0775.
Chapter 2. Diagnosing Problems 73

v Jams from Tray 1 and possibly Tray 2 or 3: Electromagnetic Clutch, Turn Roll (Asm-Index: 4-9, page 555) Turn Roll Assembly (Asm-Index: 4-10, page 555) Rear Roll Assembly (Asm-Index: 4-11, page 555) Feeder PWB (Asm-Index: 3-1, page 553) Turn Chute Assembly (Asm-Index: 3-5, page 553) Turn In Chute (Asm-Index: 3-4, page 553) Paper Cassette (Asm: 2, page 550) Tray Harness (Asm-Index: 12-17, page 575) v Jams from any Tray: Registration Sensor (Asm-Index: 7-6, page 562) Registration Actuator (Asm-Index: 7-7, page 562) High Harness Assembly (Asm-Index: 6-5, page 559) v 500-Sheet Paper Tray Option Problems: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) v 2000-Sheet Input Drawer Problems: Treat as a 26 PAPER JAM on page 94 v General: MCU PWB (Asm-Index: 12-8, page 575) Main Gear Assembly (Asm-Index: 10-10, page 570) Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)

Chapter 2. Diagnosing Problems 74

Table 17. 21 PAPER JAM


Step Actions and Questions PAPER CONDITIONS AND ADJUSTMENTS v The paper should not be curled, damaged, or damp. v The paper should t precisely within the guides of the tray cassette. If you are using the Auxiliary Tray (MSI), the PAPER MENU/AUXSIZE setting must match the size and orientation (LEF=Long Edge Feed, SEF=Short Edge Feed). Are the paper and paper adjustments OK? PAPER JAM 2. Clear all paper in the paper path. Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also see Table 58 on page 293. Is the Registration Actuator operating correctly? Go to step 3. Repair or replace the Registration Actuator (Asm-Index: 7-7, page 562). Yes Go to step 2 No Verify the x. Also verify that the problem job prints.

1.

Chapter 2. Diagnosing Problems 75

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions DETERMINE WHICH SOURCE(S) ARE INVOLVED WITH THE PAPER JAM v Load all sources with paper. v Switch the printer power ON. v If a jam message is displayed, clear the entire paper path. If an error other than 21 PAPER JAM occurs, go the appropriate error code procedure. v Set PAPER MENU/TRAYSWITCH=OFF. v During the next steps, record which sources print OK and which sources are involved with jams. Clear jams as necessary. Note that CONFIG PAGES will try a reprint after the jam is cleared. Press ONLINE to cancel. v Load Tray 1 (the standard 500 sheet input). Set the PAPER MENU/SOURCE=TRAY 1. Try to print using TEST MENU/CONFIG PAGE. If a jam occurs, clear it. v Load the Auxiliary Tray (the ip-down MSI input at the front of the printer). Ensure that PAPER MENU/ AUXSIZE matches the loaded paper size/orientation. Set PAPER MENU/SOURCE=AUX. Try to print another CONFIG PAGE. v If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeat the above steps for Tray 2. v If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat the above steps for Tray 3. Did the 21 PAPER JAM ever occur? 4. Repeat the above step using TEST MENU/CONTINUOUS TEST. (Stop the Continuous Test with the CANCEL PRINT key; 10 pages may print before the printer stops.) Is the printing OK? Go to step 6 Go to step 5 Yes Record the related print sources, and go to step 8 No Go to step 4

3.

Chapter 2. Diagnosing Problems 76

Table 17. 21 PAPER JAM (continued)


Step 5. Actions and Questions Did 21 PAPER JAM occur? Yes Record the related print sources, and go to step 8. Go to step 7 No For other errors, return to Diagnostic Quick Path on page 28. See Appendix E. Duplex Unit Option on page 604. Go to step 7

DUPLEX UNIT (Asm: 12, page 575) If a duplex option is not installed, go to step 7. 6. If a duplex option is installed, set PAPER MENU/DUPLEX=ON. Print using TEST MENU/CONTINUOUS TEST. Is duplex printing OK? PAPER OUT SENSING 7. From each source, remove all paper. Verify that printing a CONFIG PAGE from that source causes an 11 LOAD <size> IN <source> error. Is the paper out sensing for each source OK? Use the following chart to determine which step to go to (ignore references to options not installed). Aux Tray 1 Tray 2 Tray 3 Go to step: 8. OK OK bad bad OK OK OK OK bad bad bad OK OK bad bad bad bad OK bad bad 10 10 12 16 9

Possible intermittent or random problems, see page 133

Paper out sensing problem. (For 500-sheet option, replace the 500-sheet option)

TRAY 1 PRINTING IS BAD 9. Observe the position of the paper from Tray 1 after the error occurs. Did the paper start to leave the cassette?

Turn Roll problem. Go to step 21.

Pick problem. Go to step 18.

Chapter 2. Diagnosing Problems 77

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions Is the failing Tray a 500 sheet input option? Note: If Tray 2 and Tray 3 printing is bad, Tray 2 is the failing tray. 10. Yes Go to step 11 No The failing tray is the 2000-Sheet Input Drawer. Go to 26 PAPER JAM on page 711.

11.

TRAY SPRINGS v Remove the tray (cassette) from the option. Remove the paper. v Press the bottom plate down and ensure that it stays down. v Insert the tray in the option and ensure that the plate springs up. v Inspect the tray for other damage. v If another tray is available, use it for analysis. Is the tray OK? FRONT BOTTOM TRAY (Asm-Index: 5-5, page 557) You are starting analysis for jams only from the AUX Tray.

Replace the entire Replace the tray 500-Sheet input option

Go to step 14

Go to step 13

12.

a. Load paper in the Auxiliary Tray. Set PAPER MENU/SOURCE=AUX and verify PAPER MENU/AUXSIZE. Run a CONFIG PAGE. b. Inspect the Front Bottom Tray through Front Tray Opening. Is the Front Bottom Tray raised during printing?

Chapter 2. Diagnosing Problems 78

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions OPERATION OF PICK UP SOLENOID (Asm-Index: 6-17, page 559) a. Remove the EP cartridge. Close the covers, but leave the Aux Tray open b. Run D50 (see D50 SOL TRAY A (Auxiliary Tray Feed Solenoid) on page 277). From the front of the printer watch for the Aux Pick Up Solenoid try to move the cams at both ends of the shaft on the front bottom tray. Also, listen for the solenoid to pick. Does the Pick Up Solenoid operate properly? PICK UP ROLL (Asm-Index: 6-9, page 559) and RETARD PAD ASSEMBLY Go to step 15 14. a. Run another CONFIG PAGE. b. Inspect the transportation of the paper through Front Tray Opening. Does the Pick Up Roll transport the paper properly without slipping? ROTATION OF PICK UP GEAR (Asm-Index: 6-15, page 559) 15. Clean the Pick Up Replace or Roll, Retard Pad reassemble parts. a. Run another CONFIG PAGE. Assembly, and/or b. Inspect the Pick Up Gear through the narrow opening at the left end of the Transport Chute EP cartridge (is the cartridge installed?). Assembly Does the Pick Up Gear rotate once during each paper feed? REGISTRATION SENSOR 16. Use D21 SENSOR TEST on page 261 to test the Registration Sensor. Does the Registration Sensor function correctly? Go to step 17 Go to Registration Sensor on page 172 Replace Transport Chute Assembly (See page 468) Yes Go to step 14 No Replace or reassemble the Front Bottom Tray (See page 464)

13.

Chapter 2. Diagnosing Problems 79

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions The paper jams from Tray 1 and the Aux Tray, but the registration sensor is OK. Do the tests in step 3 again. Is there still a problem? TRAY 1 SPRINGS 18. You are starting analysis for Tray 1 pick problems. Check Tray 1 (refer to instructions in Step 11). Is the tray OK? FEED SOLENOID (Asm-Index: 4-8, page 555) 19. a. Run D51 (see D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid) on page 279). b. Inspect operation of the Feed Solenoid. Does the Feed Solenoid operate? FEED GEAR and FEED SOLENOID a. Run a Test Print (see page 252). b. Inspect the Feed Solenoid to actuate the Feed Gear. Does the Feed Solenoid properly actuate the Feed Gear? Unknown pick Replace the Feed problem from Tray Solenoid (See 1 page 446) Go to step 20 Go to Feed Solenoid on page 155 Go to step 19 Replace the tray Yes Paper feed problem No Go to Intermittent or Random Problems on page 133

17.

20.

Chapter 2. Diagnosing Problems 80

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions Yes No Go to step 22

CAUTION: Mechanical <2-35> Remove all watches, rings, jewelry, and other articles problem in paper (such as a necktie) that may catch on printer parts before transport working in this area. TURN ROLL ASSEMBLY (Asm-Index: 4-10, page 555) and REAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555) 21. You are starting analysis for a Tray 1 turn roll problem. a. Install the Paper Cassette without the Cassette Cover. b. Run a CONFIG PAGE. c. While the paper is transported, inspect the rolls by opening the Turn Chute Assembly (Asm-Index: 3-5, page 553) at the rear of the printer. Do the rolls turn? ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555) Go to the last step of this Run D41 (see D41 CLUTCH TR (Turn Roll Clutch) on page 269). You should diagnostic. hear a clicking sound when the clutch activates. Note: If you have a 500-Sheet Tray 2, you will hear that clutch activate also. Put your nger on the Turn Roll Shaft near the clutch while activating D41 to determine if the clutch is activating. Does the Electromagnetic Clutch function correctly? ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555) 23. Replace the Electromagnetic Clutch (See page 449). Is the problem xed?

Go to step 23

22.

Verify the x. Also Replace the verify that the Feeder PWB (See problem job page 420) prints.

Chapter 2. Diagnosing Problems 81

Table 17. 21 PAPER JAM (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

24.

Chapter 2. Diagnosing Problems 82

22 PAPER JAM
Meaning: Paper has jammed in the duplex unit. Action: Clear the jam. Error Code Diagnostic Procedure: 22 PAPER JAM (or 21 PAPER JAM from Duplex) on page 608.

Chapter 2. Diagnosing Problems 83

23 PAPER JAM
Meaning: There is a paper jam between the Registration Sensor and the Exit Sensor. Can also be caused if the paper did not reach the Exit Sensor from the Registration Sensor in the required time. Action: Clear the jam.
Table 18. 23 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor v Registration Clutch Assembly (Asm-Index: 10-9, page 570) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v BTR Assembly (Asm-Index: 6-1, page 559) v EP Cartridge (Asm-Index: 11-40, page 572) v Main Gear Assembly (Asm-Index: 10-10, page 570) v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570) v High Harness Assembly (Asm-Index: 6-5, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) 1. PAPER CONDITIONS Is the paper loaded in the paper tray wrinkled or damaged? Replace with fresh, dry paper Go to step 2 Yes No

Chapter 2. Diagnosing Problems 84

Table 18. 23 PAPER JAM (continued)


Step PAPER JAM 2. Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also see Table 58 on page 293. Is there any foreign material (such as paper) near the Registration Actuator? Actions and Questions Yes No

Remove any Go to step 3 foreign material Note: Turn the registration roll by hand to remove hard to reach paper. The paper does not reach the exit actuator. Go to step 4.

3.

PAPER POSITION The exit sensing may be bad. Go a. If the Duplex Option is installed, remove it. Note: If paper jams do not occur with the Duplex Option removed, replace to step 11. the Duplex Option. b. Print TEST MENU/CONFIG PAGE until a 23 PAPER JAM occurs. c. Open the Fuser Cover Assembly. d. Open the Fuser Rear Cover (Asm-Index: 8-10, page 564). e. Inspect the position of paper when the error code 23 PAPER JAM is displayed. Did the paper reach or pass the Exit Actuator (Asm-Index: 8-24, page 564)?

4.

Did the paper reach the Fuser?

Fuser or main gear problem. Replace the EP Cartridge. If that does not x the problem, go to step 6.

Go to step 5

TRANSPORT ASSEMBLY (Asm-Index: 7-1, page 562) 5. Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) and the Rubber Registration Roll (Asm-Index: 7-11, page 562). Do the Metal Registration Roll and the Rubber Registration Roll rotate smoothly?

Replace the Transport Chute Assembly (See page 468)

Chapter 2. Diagnosing Problems 85

Table 18. 23 PAPER JAM (continued)


Step Actions and Questions REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570) 6. Inspect paper position when Error Code 23 PAPER JAM is displayed. Did the front edge of paper pass between the Metal Registration Roll (Asm-Index: 7-10, page 562) and the Rubber Registration Roll (Asm-Index: 7-11, page 562)? REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570) Use D43 CLUTCH REG (Registration Clutch) on page 271 to check the Registration Clutch Assembly. 7. Does the Registration Clutch function properly? Go to step 8 Replace the Registration Clutch Assembly (See page 495). If the problem still exists, there is a bad MCU PWB or High Harness Assembly. Replace the Main Gear Assembly (See page 497) Yes Go to step 8 No Go to step 7

GEAR RELEASE MECHANISM OF MAIN GEAR ASSEMBLY (Asm-Index: 10-10, page 570) 8. a. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). b. Open and close the Pop Up Unit. Does the Gear Release Mechanism sink down when you open the Pop Up Unit, and rise up when you close the Pop Up Unit? ROTATION OF BTR ROLL AND EP CARTRIDGE DRUM Inspect the position of front edge of the paper. 9. Did the front edge of the paper pass between the BTR and the Drum?

Go to step 9

Go to step 10

Replace the BTR Assembly (See page 466), EP Cartridge, or the Transport Chute Assembly (See page 468)

Chapter 2. Diagnosing Problems 86

Table 18. 23 PAPER JAM (continued)


Step Actions and Questions There is a paper transport problem between the Registration Sensor and the Fuser Exit Sensor. One of the following parts is bad: v Paper Path (check for obstructions) v Main Gear Assembly (Asm-Index: 10-10, page 570) 10. v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v BTR Assembly (Asm-Index: 6-1, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. 11. FUSER ASSEMBLY (Asm-Index: 8-1, page 564) Replace the Fuser Assembly (See page 487). Note: The Fuser is part of the Usage Kit. Is the problem xed? Use D21 SENSOR TEST on page 261 to test the Exit Sensor and circuits (you will need to override the fuser cover switch). Is the sensing OK? The paper probably did not reach the sensor in time. Go to step 5. Go to step 13 Verify the x. Also Go to step 12 verify that the problem job prints. Yes No

12.

Chapter 2. Diagnosing Problems 87

Table 18. 23 PAPER JAM (continued)


Step Actions and Questions The Fuser exit sensing is bad, one of the following parts is bad: v High Harness Assembly (Asm-Index: 6-5, page 559) 13. v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

14.

Chapter 2. Diagnosing Problems 88

24 PAPER JAM
Meaning: There is a paper jam between the Paper Cassette / Auxiliary Tray and the Registration Sensor. This often occurs when another paper jam has not been completely cleared. It can also occur if the paper arrives at the sensor early due to a premature paper pick. Note: If you were running a pick/feed diagnostic, D50 SOL TRAY A (Auxiliary Tray Feed Solenoid), D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid), D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid), or D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid), the 24 PAPER JAM may have occurred because a solenoid was pre-picked. Action: Remove jammed paper from the paper path. Open and close the top cover. If this action does not x the problem, go to Table 19 on page 90.

Chapter 2. Diagnosing Problems 89

Table 19. 24 PAPER JAM


Step Actions and Questions SUSPECT COMPONENTS v Transport Chute Assembly (Asm-Index: 6-2, page 559) v Sensor Problems: Registration Sensor (Asm-Index: 7-6, page 562) Registration Actuator (Asm-Index: 7-7, page 562) v Early Pick from Auxiliary Tray: Pick Up Solenoid (Asm-Index: 6-17, page 559) v Early Pick from Tray 1: Feed Solenoid (Asm-Index: 4-8, page 555) v 500-Sheet Paper Tray Option Problems: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) v General: Feeder PWB (Asm-Index: 3-1, page 553) MCU PWB (Asm-Index: 12-8, page 575) High Harness Assembly (Asm-Index: 6-5, page 559) Feeder Harness (Asm-Index: 3-12, page 553) in Asm-Index: 3-6 Tray Harness (Asm-Index: 12-17, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) 1. Paper sizes that are not within specications can cause paper jams (See Appendix C. Media Specications on page 593). Is the paper size used within specications? Go to step 2 Replace with paper within specications Yes No

Chapter 2. Diagnosing Problems 90

Table 19. 24 PAPER JAM (continued)


Step 2. Actions and Questions Switch off printer power, and remove paper from all trays, and then switch on printer power. Does the error code appear immediately after switching ON the Main Power? PAPER JAM Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also see Table 58 on page 293. Is there any foreign material (such as paper) touching the Registration Actuator? Remove foreign Go to step 4 material Note: Turn the registration roll by hand to remove hard to reach paper. Return to step 2. REGISTRATION SENSOR (Asm-Index: 7-6, page 562) 4. Use the D21 SENSOR TEST on page 261 to check the function of the Registration Sensor. Does the Registration Sensor function correctly? DUPLEX UNIT 5. Does the problem appear only when using the Duplex Unit? Possible intermittent registration sensing problem, or a dirty sensor. Go to Appendix E. Duplex Unit Option on page 604 Go to Registration Sensor on page 172 Go to step 6 Yes Go to step 3 No Go to step 5

3.

Chapter 2. Diagnosing Problems 91

Table 19. 24 PAPER JAM (continued)


Step Actions and Questions PREMATURE PAPER PICK a. Switch off printer power. b. Add paper to all sources, including the Auxiliary tray. c. Switch on printer power. Does the error code appear immediately after switching ON the Main Power? Is there paper in the paper path? 7. Go to step 8 Yes Go to step 7 No The error may have been caused by paper that is now gone. Run TEST MENU/CONFIG PAGE to see if another occurs. Go to Registration Sensor on page 172 Go to step 9

6.

Determine which paper sources have the premature paper pick. 8. Is the problem only with the Auxiliary tray? Does the problem appear when using Tray 2 or 3?

Go to Pick Up Solenoid (Auxiliary Tray) on page 170

9.

Go to Go to step 10 Appendix G. 500-Sheet Paper Tray Option on page 661 or Appendix H. 2000-Sheet Input Drawer Option on page 703

10.

There is a premature feed problem with Tray 1. Go to Feed Solenoid on page 155.

Chapter 2. Diagnosing Problems 92

Table 19. 24 PAPER JAM (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

11.

Chapter 2. Diagnosing Problems 93

26 PAPER JAM
Meaning: Paper has jammed in the 2000-Sheet Input Drawer exit area. Action: Remove jammed paper from the paper path. Open and close the top cover. Error Code Diagnostic Procedure: 26 PAPER JAM on page 711.

27 PAPER ERROR <source>


Meaning: There is a conict between the size of paper the printer senses in a Cassette (Tray) and Auxiliary tray and the size of paper that is loaded. This can happen when the printer detects paper that seems too long (including multi-sheet feeds) or too short. This usually occurs because the user fed a size/orientation in the Auxiliary Tray that did not match the PAPER MENU/ AUXSIZE setting. If CONFIG MENU/AUTOCONTINU=ON, the error message only displays for a short time before doing an automatic continue. Action: If the AUTOCONTINU item in the Cong Menu is set to ON, printing resumes in ten seconds. Make sure paper is correctly loaded in the tray and the end guides in the tray are properly set. For the auxiliary tray, verify the AUXSIZE setting on the Paper Menu. You may need to open and close the top cover to clear the condition. If this action does not x the problem, go to Table 20 on page 95.

Chapter 2. Diagnosing Problems 94

Table 20. 27 PAPER ERROR <source>


Step Actions and Questions SUSPECT COMPONENTS v Problems with Tray 1 size sensing: Feeder PWB (Asm-Index: 3-1, page 553) Cassette Guide Assembly L (Asm-Index: 3-6, page 553), including harness Paper Cassette (Asm: 2, page 550) Tray Harness (Asm-Index: 12-17, page 575) v Problems with 500-Sheet Paper Tray option size sensing: Feeder Assembly (Asm-Index: 20-1, page 697) v General: MCU PWB (Asm-Index: 12-8, page 575) v Slow paper feeding: Transport Chute Assembly (Asm-Index: 6-2, page 559) Does the problem appear when printing from Tray 1 or a Tray 2 or a Tray Go to step 5 3 option? Does the error message appear when you feed from the Multi Sheet Inserter (Auxiliary tray)? Go to step 3 Go to step 2 Yes No

1.

2.

Go to step 4

Chapter 2. Diagnosing Problems 95

Table 20. 27 PAPER ERROR <source> (continued)


Step AUXSIZE SETTING 3. Actions and Questions Yes No Correct the AUXSIZE setting

There may be a problem causing Check the PAPER MENU/AUXSIZE setting. must match the paper size and slow paper orientation (LEF=Long Edge Feed, SEF=Short Edge Feed) of the paper in the feeding from the Auxiliary tray. Auxiliary tray. Is the setting OK? 2000-SHEET INPUT Go to Appendix H. 2000-Sheet Input Drawer Option on page 703 Go to step 6

4.

Does the problem appear when printing from the 2000-Sheet Paper Tray Option? PAPER LOADING

There is a problem with the Envelope option or an intermittent problem. Adjust the paper guides

5.

Check each paper tray and the paper guide adjustments. Does each tray have the size guides adjusted to match the loaded paper? TRAY SIZE SENSING a. Print TEST MENU/CONFIG PAGE. b. If an error occurs, press CONTINUE. c. On the CONFIG PAGE, under Auto Sensed Paper, compare the sizes listed to the paper sizes in the trays. Do the sizes match for all trays? Go to step 7

6.

Go to Paper Size Switch 500-Sheet Paper Trays on page 165

7.

Paper loading and size sensing seem OK. If the error no longer occurs, it was probably caused by a multiple sheet feed. If the error still occurs, there may be a mechanical problem causing slow paper feeding.

Chapter 2. Diagnosing Problems 96

Table 20. 27 PAPER ERROR <source> (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

8.

Chapter 2. Diagnosing Problems 97

29 OUTPUT FULL
Meaning: The output bin is full. Without a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index: 8-8, page 564) in the Fuser Assembly. When a duplex option is installed, the printer monitors the Duplex Stack Actuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator. When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed on the operator panel. The printer continues to print a few more pages to clear the paper path before it stops. The 29 OUTPUT FULL message remains until the signals indicate that the paper stack has been removed. Notes: 1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printer stops after the paper path clears. 2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the user can remove the duplex unit and continue to print simplex jobs. Action: Remove the output from the bin. If this action does not x the problem, go to Table 21.
Table 21. 29 OUTPUT FULL
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Full Stack Sensor v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v If the error only occurs with the Duplex Option, see 29 OUTPUT FULL, with Duplex Installed on page 610. Yes No

Chapter 2. Diagnosing Problems 98

Table 21. 29 OUTPUT FULL (continued)


Step PAPER STACK 1. Is there a paper stack on the Pop Up Cover Assembly close to the Full Stack Actuator (Asm-Index: 8-8, page 564)? 2. PAPER CONDITIONS Is the paper curled? DUPLEX UNIT Is the printer equipped with a Duplex Unit? 3. Actions and Questions Yes Remove paper stack No Go to step 2

Replace with fresh dry paper, and go to step 3

Go to step 3

The Full Stack Go to step 4 Sensor on the Fuser is disabled. Go to 29 OUTPUT FULL, with Duplex Installed on page 610. Go to step 5 Replace the Fuser Assembly (See page 487)

FULL STACK ACTUATOR and SENSOR (Asm-Index: 8-8 and 8-7, page 564) 4. a. Open the Fuser Cover Assembly. b. Push up and then release the Full Stack Actuator. c. Check the actuator and the sensor for correct operation. Are the actuator and the sensor OK? FULL STACK SENSOR (Asm-Index: 8-7, page 564) 5. a. Use D21 SENSOR TEST on page 261 to check the Full Stack Sensor. b. Press and release the Full Stack Actuator (Asm-Index: 8-8, page 564). Is the sensor OK?

Possible Go to step 6 intermittent or random problems, see page 133

Chapter 2. Diagnosing Problems 99

Table 21. 29 OUTPUT FULL (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. 6. FUSER ASSEMBLY (Asm-Index: 8-1, page 564) Replace the Fuser Assembly (See page 487). Is the problem xed? High Harness Assembly (Asm-Index: 6-5, page 559) v Remove the Controller Assembly (See page 535). v Disconnect P/J14 from the MCU. v Check the following for continuity: J14-8 <=> J142-A1 (at Fuser connection) J14-7 <=> J142-A2 J14-6 <=> J142-A3 Is there continuity? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Replace the MCU Replace the High (See page 526) Harness Assembly (Asm-Index: 6-5, page 559). Note: Use the removal procedure for the Transport Chute Assembly (See page 468) Yes No

Verify the x. Also Go to step 7 verify that the problem job prints.

7.

8.

Chapter 2. Diagnosing Problems 100

30 MEMORY OVERFLOW
Meaning: Memory overow. The printer has received more data than it can t into its memory. This can happen when the printer receives too many soft fonts, macros, or complex graphics. Action: If the AUTOCONTINU item in the Cong Menu is set to ON, printing resumes in ten seconds. Otherwise, press the Continue key. Check the current page for errors.

31 MEMORY ALLOC ERROR


Meaning: The printer cannot allocate the memory required to print a job. Action: If the AUTOCONTINU item in the Cong Menu is set to ON, printing resumes in ten seconds. Otherwise, press the Continue key. Check the current page for errors.

32 PRINT OVERRUN
Meaning: A page is too complex to print at the current resolution. Action: Do one of the following: v If QUALITY is set to 1200, change it to something else (such as 600) and resubmit the job. Use your printer driver or the Cong Menu. The driver setting overrides the menu setting. v If you are feeding paper long-edge rst, change it to short-edge rst. v Have the customer add more memory.

40 MEMORY OPTION ERROR


Meaning: A SIMM module is not properly seated in its slot or is defective. Action: Turn off the printer. Remove the controller card. Reseat the SIMM module. If the message recurs after you restart the printer, install a new SIMM module.

Chapter 2. Diagnosing Problems 101

41 NETWORK OPTION ERROR


Meaning: The printer detected a network interface card in the top slot, but the card is not communicating. Action: Make sure the network interface card is properly installed and restart the printer. If the same message recurs, move the network interface card to the bottom slot and restart the printer. If the message 42 NETWORK OPTION ERROR occurs, replace the network interface card. If no message occurs with the network interface card in the bottom slot, replace the Controller. Remove the network interface card from the printer if you want to print a conguration page or print from the parallel port.

42 NETWORK OPTION ERROR


Meaning: The printer detected a network interface card in the bottom slot, but the card is not communicating. Action: Make sure the network interface card is properly installed and restart the printer. If the same message recurs, move the network interface card to the top slot and restart the printer. If the message 41 NETWORK OPTION ERROR occurs, replace the network interface card. If no message occurs with the network interface card in the top slot, replace the Controller. Remove the network interface card from the printer if you want to print a conguration page or print from the parallel port.

Chapter 2. Diagnosing Problems 102

43 PS OPTION ERROR
Meaning: The printer has detected a problem with the PostScript section of the Controller SIMM. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset as follows (this resets all values in printer NVRAM to factory defaults): 1. Print a conguration page Conguration Page on page 250. 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display. If the error recurs, replace the Controller SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

44 IPDS OPTION ERROR


Meaning: The printer has detected a problem in the IPDS SIMM. Action: Reinstall the IPDS SIMM. If the message recurs, replace the IPDS SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

Chapter 2. Diagnosing Problems 103

45 OPTION ERROR
Meaning: The printer has detected a problem with a SIMM (probably the IPDS SIMM). Action: Reinstall all SIMMs. If the message recurs, replace the IPDS SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

46 NETWORK OPTION ERROR


Meaning: The printer has detected that two of the same network interface cards have been installed. Action: Remove one of the cards.

Chapter 2. Diagnosing Problems 104

50 ERROR CALL FOR SERVICE


Meaning: The printer detected a fuser problem. Action: Turn off the printer for fteen minutes and then turn on the printer. If this action does not x the problem, go to Table 22.
Table 22. 50 ERROR CALL FOR SERVICE
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. FUSER ASSEMBLY (Asm-Index: 8-1, page 564) 1. a. Install a new Fuser Assembly (See page 487). b. Switch ON the main power. Time how long it takes for READY or 50 ERROR CALL FOR SERVICE to display. Does READY appear? 2. Did 50 ERROR CALL FOR SERVICE appear within the rst minute? There is a fuser sensing problem. Go to step 3. Verify the x. Also verify that the problem job prints. If 50 ERROR CALL FOR SERVICE appeared, go to step 2. For other errors or messages, return to Chapter 1. Getting Started on page 25. There is a fuser heating problem. Go to step 4. Yes No

Chapter 2. Diagnosing Problems 105

Table 22. 50 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559) a. Disconnect P/J14 from the MCU PWB (Asm-Index: 12-8, page 575). b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). This will expose J142. c. Check for the continuity of each wire between: v J14-5 <=> J142-A4 (TEMP) v J14-4 <=> J142-B1 (SG) Is there continuity between J14 <=> J142? LVPS HARNESS (Asm-Index: 12-14, page 575) 4. a. Disconnect P/J121 from the LVPS Assembly (Asm-Index: 12-4, page 575) and P/J11 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check for the continuity of each wire between J11 <=> J121. Is there continuity between J11 <=> J121? Go to step 5 Replace the LVPS Harness Yes No

Replace the MCU Replace the High (See page 526 or Harness 529) Assembly

3.

Chapter 2. Diagnosing Problems 106

Table 22. 50 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559) a. Disconnect P/J124 from the LVPS Assembly (Asm-Index: 12-4, page 575). 5. b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). This will expose J142. c. Activate the Fuser Cover Switch, and check for continuity between: v P/J124-3 <=> P/J142-3 (AC N) v P/J124-1 <=> P/J142-1 (AC L) Is there continuity between J124 <=> J142? LVPS ASSEMBLY (Asm-Index: 12-4, page 575) 6. Replace the LVPS (See page 521). Problem xed? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Verify the x. Also Replace the MCU verify that the (See page 526 or problem job 529) prints. Yes Go to step 6 No Replace the Fuser Cover Switch (See page 516) or the wires and connector, or the High Harness Assembly (See page 521).

7.

Chapter 2. Diagnosing Problems 107

51 ERROR CALL FOR SERVICE


Meaning: There is a problem with the ROS (Printhead) Assembly. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, go to Appendix D. Technical Support on page 602.

Chapter 2. Diagnosing Problems 108

52 ERROR CALL FOR SERVICE


Meaning: There is a problem with the ROS (Printhead) Assembly. Action: Power off the printer, wait twenty seconds, then power on. If this action does not x the problem, go to Table 23.
Table 23. 52 ERROR CALL FOR SERVICE
Step Actions and Questions SUSPECT COMPONENTS v POP-UP/ROS Assembly (Asm-Index: 11-20, page 572) v CRU Sensor Assembly (Asm-Index: 11-15, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572) Go to step 2 Note: The CRU Sensor Assembly has a switch to detect the presence of the EP cartridge and an LD switch that disables the ROS Laser Diode when the cartridge is removed. 1. a. Run D21 SENSOR TEST on page 261 to test the CRU sensor and circuits. Note: Test D21 does not test the LD switch. b. Open and close the Pop Up Unit. Is sensing OK? 2. Remove the controller, and verify that connector P/J12 (ROS) at the MCU is OK. Are the connectors OK? Go to step 3 Repair as needed Replace the CRU Sensor Assembly, which includes the Harness (See page 503) Yes No

Chapter 2. Diagnosing Problems 109

Table 23. 52 ERROR CALL FOR SERVICE (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. LASER DIODE POWER a. Unplug P/J12. b. Install the EP Cartridge (Asm-Index: 11-40, page 572). c. Close the Pop Up Unit. d. Check the voltage between P12-7 (5VDC-LD)<=> P12-6 (SG) on the MCU PWB (Asm-Index: 12-8, page 575). Is there +5 VDC between P12-7 <=> P12-6? DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 4. LASER DIODE POWER SUPPLY OF ROS ASSEMBLY (Asm-Index: 11-20, page 572) Check the voltage between P12-2 <=> P12-6. Is there 5VDC between P12-2 <=> P12-6? Go to step 6 Go to step 5 Actions and Questions Yes Go to step 4 No Replace the MCU PWB (See page 526 or 529), or the LVPS Assembly (See page 521).

3.

Chapter 2. Diagnosing Problems 110

Table 23. 52 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions CONTINUITY ON MCU PWB 5. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). Check for the continuity between P11-2 <=> P12-1. Is there continuity between P11-2 <=> P12-1? DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 6. SOS POWER SUPPLY OF ROS ASSEMBLY (Asm-Index: 11-20, page 572) a. Disconnect P/J15. b. Check the voltage between P/J12-10 <=> P/J12-8. Is there 5VDC between P/J12-10 <=> P/J12-8? Go to step 7 LVPS problem, go to LVPS on page 163. Yes No

Replace the LVPS Replace the MCU Assembly (See PWB (See page page 521), or the 526 or 529) LVPS Harness.

Chapter 2. Diagnosing Problems 111

Table 23. 52 ERROR CALL FOR SERVICE (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 7. SCANNER ASSEMBLY POWER SUPPLY Check the voltage between P12-15 <=> P12-14. Is there 24VDC between P12-15 <=> P12-14? CONTINUITY ON MCU PWB a. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check for the continuity between P12-15 <=> P21-1. Is there continuity between P12-15 <=> P21-1? Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529) Actions and Questions Yes Go to step 9 No Go to step 8

8.

Chapter 2. Diagnosing Problems 112

Table 23. 52 ERROR CALL FOR SERVICE (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. SCANNER MOTOR ON SIGNAL a. Switch OFF the Main Power. b. Leave P/J15 disconnected. c. As you switch on the power in the next step, observe the voltage between P/J12-13 <=> P/J12-14. d. Switch ON the Main Power. Is there 4.1VDC between P/J12-13 <=> P/J12-14 when you switch on the Main Power? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Actions and Questions Yes Go to step 10 No Replace the MCU PWB (See page 526 or 529)

9.

10.

Chapter 2. Diagnosing Problems 113

53 ERROR CALL FOR SERVICE


Meaning: There is a problem with the Main Motor. Action: Power off the printer, wait twenty seconds, then power on. If this action does not x the problem, go to Table 24.
Table 24. 53 ERROR CALL FOR SERVICE
Step Actions and Questions SUSPECT COMPONENTS v Main Motor (Asm-Index: 10-6, page 570) v MCU PWB (Asm-Index: 12-8, page 575) v Main Gear Assembly (Asm-Index: 10-10, page 570) v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570) v EP Cartridge (Asm-Index: 11-40, page 572) v Fuser Assembly (Asm-Index: 8-1, page 564) v Feeder Assembly (Asm-Index: 20-1, page 697) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v Rear Roll Assembly (Asm-Index: 4-11, page 555) v Turn Roll Assembly (Asm-Index: 4-10, page 555) v Feed Shaft Assembly (Asm-Index: 4-2, page 555) Note: The Main Motor runs when the printer power is switched on, and stops after the fuser reaches operating temperature. Yes No

Chapter 2. Diagnosing Problems 114

Table 24. 53 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions MAIN MOTOR START (Asm-Index: 10-6, page 570) a. Switch off printer power. b. Remove the Controller Assembly (See page 535). c. Close all interlocks d. Switch on printer power. Does the Main Motor start or try to start? MAIN MOTOR (Asm-Index: 10-6, page 570) 2. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwise manually. The magnets in the Main Motor will cause pulsing resistance. Does the Main Motor rotate smoothly without binding? TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559) a. Open the Pop Up Unit. b. Remove the EP Cartridge (Asm-Index: 11-40, page 572). 3. c. Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) and Rubber Registration Roll (Asm-Index: 7-11, page 562) manually, turning the gears at the end of the metal roll. Do the Metal Registration Roll and Rubber Registration Roll rotate smoothly? REAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555) and TURN ROLL ASSEMBLY (Asm-Index: 4-10, page 555) 4. a. Open the Turn Chute Assembly. b. Rotate the Rear Roll and the Turn Roll manually. Do the Rear Roll and the Turn Roll rotate smoothly? Go to step 5 Replace the Rear Roll Assembly (See page 453) or the Turn Roll Assembly (See page 451) Go to step 4 Replace the Transport Chute Assembly (See page 468) Go to step 3 Go to step 7 Yes Go to step 2 No Go to step 12

1.

Chapter 2. Diagnosing Problems 115

Table 24. 53 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions PICK UP ROLL ASSEMBLY (Asm-Index: 6-8, page 559) 5. a. Press down the Armature of the Pick Up Solenoid (Asm-Index: 6-17, page 559). b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwise manually. Does the Pick Up Roll Assembly rotate smoothly? FEED SHAFT ASSEMBLY (Asm-Index: 4-2, page 555) a. Press down the armature of the Feed Solenoid (Asm-Index: 4-8, page 555). Note: The Feed Solenoid is located behind the MCU PWB, near the lower left corner. b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwise manually. c. Inspect the rotation of the Feed Gear (Asm-Index: 4-5, page 555). Does the Feed Gear rotate smoothly? EP CARTRIDGE (Asm-Index: 11-40, page 572) 7. a. Remove EP Cartridge. b. Rotate the rotor of Main Motor (Asm-Index: 10-6, page 570) clockwise manually. Does the rotor of Main Motor rotate smoothly? Replace the EP Cartridge (Asm-Index: 11-40, page 572) Go to step 8 Go to step 12 Replace Gears, etc. which may disturb the rotation (See page 438, 442, or 446) Yes Go to step 6 No Replace the Transport Chute Assembly (See page 468)

6.

Chapter 2. Diagnosing Problems 116

Table 24. 53 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. 8. FUSER ASSEMBLY (Asm-Index: 8-1, page 564) a. Remove the Fuser Assembly (See page 487). b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwise manually. Does the rotor of the Main Motor rotate smoothly? FEEDER ASSEMBLY (Asm-Index: 20-1, page 697) a. Remove the Out Idler Gear (Asm-Index: 4-16, page 555). 9. b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwise manually. Does the rotor of the Main Motor rotate smoothly? PAPER HANDLING GEAR ASSEMBLY (Asm-Index: 10-7, page 570) 10. a. Remove the Paper Handling Gear Assembly (See page 492). b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570). Does the rotor of the Main Motor rotate smoothly? MAIN MOTOR (Asm-Index: 10-6, page 570) 11. a. Remove the Main Motor from the printer frame (See page 489). b. Rotate the rotor of the Main Motor. Does the rotor of the Main Motor rotate smoothly? Replace the Main Replace the Main Gear Assembly Motor (See page (Asm-Index: 489). 10-10, page 570). Replace the Paper Handling Gear Assembly (See page 492). Go to step 11 Replace the Go to step 10 Feeder Assembly (See page 666) Yes Replace the Fuser Assembly (See page 487) No Go to step 9

Chapter 2. Diagnosing Problems 117

Table 24. 53 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions MAIN MOTOR HARNESS a. Disconnect P/J16 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check the resistance between J16-1 <=> J16-2. Is there approximately 14 K ohms between J16-1 <=> J16-2? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

12.

Replace the Main Replace the Main Motor (See page Motor (See page 489), or the MCU 489) PWB (See page 526 or 529)

13.

Chapter 2. Diagnosing Problems 118

54 ERROR CALL FOR SERVICE


Meaning: The printer has detected a problem in the duplex unit. Action: Make sure the duplex unit is installed correctly. If the problem continues, suspect the following components: v Duplex Unit (Asm-Index: 30-1, page 652) v Controller PWB (Asm-Index: 13-6, page 578) v MCU PWB(Asm-Index: 12-8, page 578)

Chapter 2. Diagnosing Problems 119

55 ERROR CALL FOR SERVICE


Meaning: The Fan is not rotating. The Fan rotates at Low Speed when printer power is switched on. The Fan rotates at High Speed when the Main Motor is switched on. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs. If this action does not x the problem, go to Table 25.
Table 25. 55 ERROR CALL FOR SERVICE
Step Actions and Questions SUSPECT COMPONENTS v Fan (Asm-Index: 12-3, page 575) 1. v LVPS Assembly (Asm-Index: 12-4, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) Inspect the fan. Is it OK? FAN (Asm-Index: 12-3, page 575) Replace the Fan (See page 518). 2. Is the problem xed? Verify the x. Also verify that the problem job prints. See MCU LVPS INTERLOCK SWITCH and FANs on page 311, or run D23 (see D23 TEST FAN on page 267). Yes Go to step 2 No Replace the Fan (See page 518)

Chapter 2. Diagnosing Problems 120

Table 25. 55 ERROR CALL FOR SERVICE (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

3.

Chapter 2. Diagnosing Problems 121

56 ERROR CALL FOR SERVICE


Meaning: There is problem with NVRAM in the MCU. Action: Power off the printer, wait twenty seconds, then power on. If this action does not x the problem, go to Table 26.
Table 26. 56 ERROR CALL FOR SERVICE
Step Actions and Questions SUSPECT COMPONENTS v MCU PWB (Asm-Index: 12-8, page 575) Switch the printer power off, then on. If using Letter size paper, press ONLINE during printer power-up. If using A4 size paper, press CANCEL during printer power-up. Note: If the printer powers on without error, print a CONFIG PAGE. Does the printer become READY? 2. Does the 56 ERROR CALL FOR SERVICE appear? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Problem xed, or Go to step 2 possible intermittent or random problems (See page 133) Replace the MCU Go to Chapter 1. (See page 526) Getting Started on page 25 Yes No

1.

3.

Chapter 2. Diagnosing Problems 122

61 ERROR CALL FOR SERVICE


Meaning: The printer has detected an error in the Controller SIMM checksum. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset as follows (this resets all values in printer NVRAM to factory defaults): 1. Print a conguration page Conguration Page on page 250. 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display. If the error recurs, replace the Controller SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

62 ERROR CALL FOR SERVICE


Meaning: The printer has detected an error in the DRAM. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs. If the message recurs, replace the DRAM SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

Chapter 2. Diagnosing Problems 123

63 ERROR CALL FOR SERVICE


Meaning: The printer has detected an error in the NVRAM (EEPROM). Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset as follows (this resets all values in printer NVRAM to factory defaults): 1. Print a conguration page Conguration Page on page 250. 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display. If the error recurs, replace the Controller SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).

71 DISK ERROR
Meaning: The printer has detected a problem with the hard drive. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.

72 DISK ERROR
Meaning: The printer has detected a problem with the hard drive. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.
Chapter 2. Diagnosing Problems 124

73 DISK ERROR
Meaning: The printer has detected a problem with the hard drive. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.

80 ADD MEMORY FOR IPDS


Meaning: The printer requires more memory before it can process IPDS jobs. Action: Have the customer install more memory.

80 ADD MEMORY FOR PAGES, ESC/P


Meaning: The printer requires more memory before it can process PAGES and ESC/P jobs Action: Have the customer install more memory.

81 INSUFFICIENT MEMORY FOR IPDS


Meaning: The printer does not have enough memory to process IPDS jobs. Action: Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the error recurs, the customer may need to install more memory.

81 INSUFFICIENT MEMORY FOR PAGES


Meaning: The printer does not have enough memory available to process PAGES, ESC/P jobs. Action: Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the error recurs, the customer may need to install more memory.

Chapter 2. Diagnosing Problems 125

82 HOST TIMEOUT
Meaning: The coax network interface card has sent an Intervention Required message to the host. This error occurs when (a) the printer is OFFLINE for longer than the HLD TMEOUT setting in the Coax Setup Menu, or (b) the printer has been in an intervention required state (such as out of paper) for longer than the IRQ TMEOUT setting. Action: Solve the problem that caused the message (for example, press the Online key to put the printer online, or add paper). To disable this error message, set the HLD TMEOUT and IRQ TMEOUT values in the Coax Setup Menu to 0.

83 CX SEND STATE
Meaning: Your coax host has placed your printer in Send State and is waiting for the printer to return a PA signal. Action: Press the Continue key to clear the message. (You may need to press the key more than once.) Then do the following to send the PA signal. 1. Press the Online key to take the printer offline. 2. Press the Menu key until you see the Coax SCS Menu. 3. Press the Item key until you see PA1 or PA2 (whichever signal you want to send). 4. Press the Enter key to send the signal. 5. Press the Online key to resume printing.

84 NO FONT SIMM FOR PAGES, ESC/P


Meaning: The printer has detected that Japanese Heisei font SIMM is not installed. Action: Power off the printer, install a Japanese Heisei font SIMM, and then power on the printer.

Chapter 2. Diagnosing Problems 126

Printer Problems without Error Codes


Fuse or Power Problem
The fan does not rotate, the motors never turn on, and the operator panel is blank. The printer does not function.

Chapter 2. Diagnosing Problems 127

Table 27. Fuse or Power Problem


Step Actions and Questions SUSPECT COMPONENTS v LVPS Assembly (Asm-Index: 12-4, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v Interlock Switch (Asm-Index: 12-1, page 575) v Fan (Asm-Index: 12-3, page 575) v Console Assembly (Asm-Index: 1-18, page 548) v ROS Assembly (Asm-Index: 11-20, page 572) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v MSI No Paper Sensor (Asm-Index: 5-9, page 557) v Fuser Assembly (Asm-Index: 8-1, page 564) v HVPS (Asm-Index: 12-11, page 575) v Main Motor (Asm-Index: 10-6, page 570) v CRU Sensor Assembly (Asm-Index: 11-15, page 572) v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v Feeder PWB (Asm-Index: 3-1, page 553) v Feed Solenoid (Asm-Index: 4-8, page 555) v Electromagnetic Clutch (Asm-Index: 4-9, page 555) v Cassette No Paper Sensor (Asm-Index: 3-11, page 553) Yes No

Chapter 2. Diagnosing Problems 128

Table 27. Fuse or Power Problem (continued)


Step AC POWER CORD Plug the AC Power Cord into the back of the printer, and the other end into an AC wall outlet. Note: If there is a 2000-Sheet Paper Tray Option installed, there are two power cords and two power switches. One cord connects the option to the wall outlet, and the other connects the option to the printer. AC power is present at both machines even when both power switches are turned off. Switch on the power switches. Does the problem still exist? AC POWER 2. Check the voltage at the AC wall outlet. The acceptable voltage ranges are: v Low voltage: 100127 V ac v High voltage: 220240 V ac Is the measured voltage OK? CONTROLLER a. Remove the Controller Assembly (See page 535). 3. b. Switch ON the Main Power. c. Observe the Fan (Asm-Index: 12-3, page 575). Does the Fan rotate? There is a problem with the controller, a controller option, or the console. Go to step 4 Go to step 3 Notify customer or their electrician. Actions and Questions Yes Go to step 2 No Verify the x. Also verify that the problem job prints. Note: If there is a different symptom, go to Chapter 1. Getting Started on page 25.

1.

Chapter 2. Diagnosing Problems 129

Table 27. Fuse or Power Problem (continued)


Step Actions and Questions LVPS OR LVPS FUSE (Asm-Index: 12-4, page 575) a. Remove the LVPS Assembly (See page 521). 4. b. Remove the fuse, located near the power switch. c. Check the continuity of the fuse. Is the fuse OK? LVPS FUSE Blown fuse. This can be caused by a defective LVPS, a defective FRU connected to the LVPS, or an overcurrent condition that no longer exists. a. Install a new fuse (10A). If a fuse is not available, install a new LVPS. b. Disconnect P/J11 from the MCU Assembly. Ensure that the fan is connected to the LVPS (P/J122). Does the Fan rotate? MCU CIRCUITS a. Connect P/J11. b. Switch on the printer power. 6. Does the Fan rotate? The blown fuse was the problem. If the fuse blows again later, go to step 7. The fuse blew again. One of the MCU loads is causing a problem. Obtain more fuses, and diagnose by sequentially connecting the connectors listed in step 7. The fuse is OK. There may be another problem that blew the original fuse. Go to step 6. Go to step 7 Yes No

Replace the LVPS Go to step 5 Assembly (See page 521)

5.

Chapter 2. Diagnosing Problems 130

Table 27. Fuse or Power Problem (continued)


Step Actions and Questions LVPS (Asm-Index: 12-4, page 575) Replace the LVPS Assembly (See page 521) Other components that can blow the fuse: v At v At the LVPS: P/J122: to the fan the MCU: P/J11: to the LVPS (and all of the following) P/J12: to the ROS Assembly P/J13: to the Registration Clutch, Registration Sensor, No Paper Sensor and Pick Up Solenoid P/J14: to the Fuser Assembly P/J15: to the HVPS P/J16: to the Main Motor P/J18: to the Interface PWB or to Fuser Cover Switch P/J19: to the Console Panel P/J20: to the Feeder PWB P/J31: to the Controller Assembly Controller, Controller option, or console. Yes No

7.

Chapter 2. Diagnosing Problems 131

Table 27. Fuse or Power Problem (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

8.

Chapter 2. Diagnosing Problems 132

Intermittent or Random Problems


Gather as much information as possible (see Dening the Problem on page 26). Closely inspect the suspected area, assembly, or part. You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post an error code. Check the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Is the printer plugged into a recommended AC outlet? Is the AC power at the outlet within specications? Is the AC power cord connected to the printer? Is the AC power cord in good condition; not frayed or broken? Is the printer grounded through the AC outlet? Is recommended paper stock used in the printer? Is the printer in an area where the temperature and humidity are moderate and stable? Is the printer in an area that is free of dust? Is the printer in an area away from water outlets, steamers, electric heaters, volatile gases, or open ames? Is the printer shielded from the direct rays of the sun? Does the printer have recommended space around all sides for ventilation? Is the printer on a level and stable surface? Does the customer use the printer as instructed in the customer documentation? Are consumables, such as the EP Cartridge, replaced at recommended intervals?

If you suspect a controller problem, see Operator Panel, Controller, and Power Problems on page 135.

Chapter 2. Diagnosing Problems 133

If you do not resolve the problem, return to Diagnostic Quick Path on page 28 and dene the problem again or call 18003586661 for technical support. If you exchange a part and the problem is not xed, reinstall the original part. Check the following: v v v v Disconnect and reseat connectors in the associated area. Check for loose, worn, or broken connectors and cables. Check the environment, such as ambient temperature and humidity. Check for RF noise such as a radio or TV transmitter.

Chapter 2. Diagnosing Problems 134

Operator Panel, Controller, and Power Problems


Use this diagnostic to solve problems which involve a blank or inoperative operator panel, light or dark rectangles displayed in operator panel, and power problems.
Table 28. Operator Panel, Controller, and Power Problems
Step Actions and Questions SUSPECT COMPONENTS v DRAM SIMM (Asm-Index: 100-1417, page 585) v Controller SIMM (Asm-Index: 100-4, page 585) v Controller PWB (Asm-Index: 13-6, page 578) v LVPS Assembly (Asm-Index: 12-4, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) v MCU PWB (Asm-Index: 12-8, page 575) Yes No

Chapter 2. Diagnosing Problems 135

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step Actions and Questions The following should happen at a normal power-up (no network cards, no errors): 1. IBM INFOPRINT 20 displays soon after the power is switched on. 2. The fan turns at low speed. 3. The motor turns, causing the exit rolls to move (whenever the motor turns, the fan runs at high speed). 4. All LEDs momentarily turn on and WARMING UP... displays after approximately 12 seconds. 5. The motor stops. 6. WARMING UP... continues to display until the fuser warms up (can last longer than 1 minute if the printer is cold). 7. The ONLINE LED blinks. 8. After the fuser warms up, the ONLINE LED stays on and READY displays on the LCD (if a NIC card is installed, I/O INITIALIZING may display for several minutes). 9. Pressing the ONLINE key causes the printer to go off-line. (OFFLINE displays on the LED and the ONLINE LED is off.) 10. Menu/item/value keys allow menu navigation. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the display. After several minutes, unrequested blank pages, or pages with black stripes may print. Yes No

Chapter 2. Diagnosing Problems 136

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step Actions and Questions Switch on the printer power and wait 5 minutes to ensure that the symptom does not change. Look for light, solid rectangles on the top line of the display. These rectangles may be very light; switch off printer power and compare to ensure that you do have these rectangles when the printer is switched on. Is the symptom solid rectangles on the top line of the display? SIMMs a. Reseat the Controller SIMM (OS, PCL, and PS). b. Reseat 1 DRAM SIMM. c. Remove the Controller options, if installed (second DRAM SIMM, third DRAM SIMM, IPDS SIMM, ash memory SIMM, and the hard drive). Is the problem xed? DRAM SIMM 3. Move the DRAM SIMM to another socket within the group of 3 sockets. Is the problem xed? If the user Go to step 4 requires 3 DRAM sockets, replace the Controller PWB (See Controller PWB on page 537). Reinstall the Go to step 3 Controller option SIMMS, one at a time, to determine which fails. Yes Go to step 2 No Go to step 6

1.

2.

4.

If the printer had only 1 DRAM SIMM, replace the SIMM (see Controller PWB The DRAM SIMM Go to step 5 SIMM on page 539). was bad Is the problem xed?

Chapter 2. Diagnosing Problems 137

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step Actions and Questions Replace the Controller SIMM (See Controller PWB SIMM on page 539). Is the problem xed? 5. Yes The Controller SIMM was bad No The Controller PWB is probably bad. Run Test Printing a Test Matrix Page Without the Controller on page 252 to verify that the problem is the Controller and not the MCU. Go to step 7

Is the symptom a continuous I/O INITIALIZING message? 6.

Go to Ethernet / Token-Ring NIC Printing Problems on page 150 Go to step 8

7.

Is the symptom a continuous WARMING UP or a continuous IBM INFOPRINT 20 message?

Go to step 10

Chapter 2. Diagnosing Problems 138

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step Actions and Questions Solid rectangles usually indicate a controller problem, and WARMING UP... or IBM INFOPRINT 20 being displayed usually indicates an MCU problem. Test the MCU by performing Printing a Test Matrix Page Without the Controller on page 252. Do the test pages print OK? 8. Yes No

The MCU is Go to step 9 functioning correctly. Replace the Controller SIMM (See Controller PWB SIMM on page 539). If the problem still exists, replace the Controller PWB (See Controller PWB on page 537). The MCU is functioning correctly. Replace the Controller SIMM (See Controller PWB SIMM on page 539). If the problem still exists, replace the Controller PWB (See Controller PWB on page 537). Bad MCU or 5V power problem. Go to LVPS on page 163.

9.

Rerun Printing a Test Matrix Page Without the Controller, ensuring that the following are true: a. The paper path is clear. b. The EP cartridge is installed. c. Paper is loaded in Tray 1. d. The covers are closed. Do the test pages print OK?

Chapter 2. Diagnosing Problems 139

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step 10. Actions and Questions Yes No Go to step 15

Ensure that there are no paper jams, and that all covers are closed. Switch off Go to step 11 the printer power, then switch it back on. Do both the fan and motor activate? CONSOLE/OPERATOR PANEL Go to step 14

Go to step 12

11.

Wait one minute, watching the 4 lighted LEDs and display. Do the LEDs and display function correctly?

12.

Verify the connection at the console assembly and the controller. If the connections seem OK, replace the console assembly (See page 418). Is the problem xed? There is a problem with one of the following components: v Console Harness (Asm-Index: 13-6, page 578) v Controller Harness (Asm-Index: 13-8, page 578) v LVPS Assembly (Asm-Index: 12-4, page 575) When Online is pressed, the Online LED should turn off. The other keys control menus. Do the keys function correctly?

Verify the x. Also Go to step 13 verify that the problem job prints.

13.

14.

Verify the x. Also Go to step 12 verify that the problem job prints. Go to LVPS on page 163 Go to Fuse or Power Problem on page 127

15.

Does the fan turn on?

Chapter 2. Diagnosing Problems 140

Table 28. Operator Panel, Controller, and Power Problems (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

16.

Chapter 2. Diagnosing Problems 141

Toner Low and No Error Code 02 Displayed


02 is not displayed when the EP Cartridge is empty.
Table 29. 02 Not Displayed
Step Actions and Questions SUSPECT COMPONENTS v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v EP Cartridge (Asm-Index: 11-40, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v MSI Bracket Assembly (Asm-Index: 5-7, page 557) v Toner Sensor Harness (Asm-Index: 5-17, page 557) v Toner Relay Harness (Asm-Index: 12-18, page 575) EP CARTRIDGE (Asm-Index: 11-40, page 572) 1. a. Run a Test Print. b. Inspect the print quality. Does the print appear light due to an empty EP Cartridge? TONER SENSOR (Asm-Index: 5-14, page 557) 2. a. Use D21 SENSOR TEST on page 261 to check the function of the Toner Sensor. Note: Activate the sensor with a non-magnetized piece of steel. Does the Toner Sensor function correctly? Go to step 3 Go to Toner Sensor on page 176 Go to step 2 Problem does not exist. Yes No

Chapter 2. Diagnosing Problems 142

Table 29. 02 Not Displayed (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

3.

Chapter 2. Diagnosing Problems 143

Other Diagnostics
These are secondary diagnostics branched to by other diagnostics.

24V Power Supply to MCU


Table 30. 24V Power Supply to MCU
Step Actions and Questions SUSPECT COMPONENTS v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v EP Cartridge (Asm-Index: 11-40, page 572) v Fuser Assembly (Asm-Index: 8-1, page 564) v Heater Assembly (Asm-Index: 9-5, page 567) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v High Harness Assembly (Asm-Index: 6-5, page 559) HARNESS a. Remove the Controller Assembly (See page 535). 1. b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575) and P/J123 from the LVPS Assembly (Asm-Index: 12-4, page 575). c. Close the Pop Up Unit. d. Check for the continuity between J21-1 <=> J123. Is there continuity between J21 <=> J123? Go to step 2 Replace the Interlock Switch (See page 513) Yes No

Chapter 2. Diagnosing Problems 144

Table 30. 24V Power Supply to MCU (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 2. LVPS ASSEMBLY a. Disconnect P/J126. b. Switch ON the Main Power. c. Check the voltage between J123 <=> J126-2. Is there 24VDC between J123 <=> J126-2? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Actions and Questions Yes Go to step 3 No Replace the LVPS Assembly (See page 521)

3.

Chapter 2. Diagnosing Problems 145

Electrical Noise
Table 31. Electrical Noise
Step Actions and Questions SUSPECT COMPONENTS v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v EP Cartridge (Asm-Index: 11-40, page 572) v Fuser Assembly (Asm-Index: 8-1, page 564) v Heater Assembly (Asm-Index: 9-5, page 567) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v High Harness Assembly (Asm-Index: 6-5, page 559) EXTERNAL NOISE a. Check if there is other electrical equipment, such as electrical generators, radio transmitters, or devices using electrical motors, within ten feet of the printer. b. Shut off the other electrical equipment, or relocate the printer at least twenty feet away from other devices. Is the Electrical Noise problem still present? AC GROUND 2. Check the AC wall outlet. Is the AC wall outlet correctly wired and grounded? Go to step 3 Have the customer repair the AC wall outlet Go to step 2 Verify the x. Also verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 146

Table 31. Electrical Noise (continued)


Step EP CARTRIDGE 3. Replace the EP Cartridge. Is the Electrical Noise problem still present? LVPS ASSEMBLY (Asm-Index: 12-4, page 575) 4. Inspect the grounding screw for the cable connected to the Main Power Switch. Is the cable grounded properly? CRU GUIDE ASSEMBLY L (Asm-Index: 11-30, page 572) 5. a. Install the EP Cartridge. b. Inspect the spring contact on the CRU Guide Assembly L with the plate terminals on the EP Cartridge. Is the spring clean and does it contact the plate properly? CRU GUIDE ASSEMBLY R (Asm-Index: 11-31, page 572) 6. a. Remove the EP Cartridge. b. Inspect the ground spring on the rear end of the CRU Guide Assembly R (Asm-Index: 11-31, page 572). Is the ground spring intact free of contamination and deformation? TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559) 7. a. Remove the Transport Chute Assembly (See page 468). b. Check for the continuity on all the wires in the Transport Chute Assembly. Is there continuity on all the wires? Go to step 8 Replace the Transport Chute Assembly (See page 468) Go to step 7 Clean the ground spring or replace the CRU Guide Assembly R (See page 510) Go to step 6 Replace the CRU Guide Assembly L (See page 506) Go to step 5 Actions and Questions Yes Go to step 4 No Verify the x. Also verify that the problem job prints. Attach the grounding screw properly

Chapter 2. Diagnosing Problems 147

Table 31. Electrical Noise (continued)


Step Actions and Questions Yes No Connect the wires properly.

8.

DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page Go to step 9 559) Inspect the DTS and the TR wires. Are the wires connected properly? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. Go to step 10

Attach the cables properly

9.

HEATER ASSEMBLY (Asm-Index: 9-5, page 567) Inspect the cables of P142-1 and the right end of the Heater Rod. Are the cables attached properly? HVPS a. Remove the Controller Assembly (See page 535). Replace the HVPS (See page 532) Go to step 11

10.

b. Disconnect P/J15 from the MCU PWB (Asm-Index: 12-8, page 575). c. Run a Test Print (continuously approximately ten sheets). Do the Test Prints run normally? Replace the MCU PWB (See page 526 or 529)

Go to step 12

11.

Is the problem still present? Inspect all of the grounds in the printer. Are the grounds proper? Replace the Suspect Components

Verify the x. Also verify that the problem job prints. Repair the bad grounds

12.

Chapter 2. Diagnosing Problems 148

Table 31. Electrical Noise (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

13.

Chapter 2. Diagnosing Problems 149

Ethernet / Token-Ring NIC Printing Problems


Note: If the network interface card is installed, but not connected to the LAN, a page with network interface card details will be printed. You can also print this page from the Test Menu.
Table 32. Ethernet/Token-Ring NIC Printing Problems
Step 1. Actions and Questions Is the problem only with IPDS jobs? Note: To answer this questions, you may need to ask the System Administrator to send a PCL or PS job. Print a Cong Page (see Conguration Page on page 250). Is IPDS indicated on the Cong Page? 2. Yes Go to step 2 No Go to step 3

There is probably a conguration problem. Refer the System Adminstrator to Ethernet and Token Ring Quick Conguration Guide, G544-5499. Go to step 4

Reseat the IPDS SIMM. If that does not x the problem, install a new IPDS SIMM.

3.

Switch on the printer power. Wait for the READY message. Wait for the full 5 minutes (you may get an error code after the printer times out). Does READY appear within 5 minutes?

Return to Diagnostic Quick Path on page 28 with the new error code or symptom.

Chapter 2. Diagnosing Problems 150

Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)


Step Actions and Questions If a NIC conguration page prints approximately 2 minutes after power is switched on, the NIC is working correctly. But there is probably a problem in the LAN connection for that NIC. Did a NIC Conguration page print for each installed NIC? Note: If your printer has both Ethernet and a token ring NIC, determine which NIC conguration page printed. A NIC conguration page will be printed for a NIC that has a LAN connection problem. Yes The printer and NIC are OK. If the problem still exists, problems, there is probably a LAN cable or LAN conguration problem. Refer the System Adminstrator to Ethernet and Token Ring Conguration Guide, G544-5240. Try to print a conguration page for the printer (not a NIC conguration page) using TEST MENU/CONFIG PAGE. 5. Does the TEST MENU/CONFIG PAGE print? Verify that each Network Interface Card has a unique IP address. Go to step 6 Return to Chapter 1. Getting Started on page 25 with the new error code or symptom. Go to step 9 No Go to step 5

4.

6.

Look at the printer conguration page. Is each installed NIC indicated on Go to step 7 the printer conguration page? Can you print a NIC Cong Page for each installed NIC from the printer (TEST MENU/PRINT EN CONFIG or TEST MENU/PRINT TR CONFIG)? Go to step 8

7.

Go to step 9

Chapter 2. Diagnosing Problems 151

Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)


Step Actions and Questions The printer and NIC seem OK. Check the LEDs on the back of the NIC; they should be as follows: v Token ring RING NSRT = ON SPD ERROR = OFF v Ethernet UTP (10base-T) LINK = on and NET ACT = on (ashes intermittently) BNC (10base2) LINK = off and NET ACT = on (ashes intermittently) Do the LEDs match the properly connected denition? Yes The printer, NIC, and LAN connection seem OK. Suspect a job or conguration problem. Refer the System Adminstrator to Ethernet and Token Ring Conguration Guide, G544-5240. No There is a LAN cabling conguration problem. Refer the System Adminstrator to Ethernet and Token Ring Conguration Guide, G544-5240.

8.

9.

The NIC that is not shown on the printer conguration page, or the Controller has a problem. v Power off. v Reseat the NIC. v Power on and wait for 5 minutes. Is the problem xed?

Verify the x. Also Go to step 10 verify that the problem job prints.

Chapter 2. Diagnosing Problems 152

Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)


Step Actions and Questions Reset the NIC jumpers as follows: a. Switch off printer power. b. Remove the NIC. c. Move jumper JX1 to the RST (reset) position. d. Reinstall the NIC. e. Switch on printer power and wait until READY displays. f. Switch off printer power. g. Move jumper JX1 to the original position. h. Reinstall the NIC. Is the problem xed? Install a new NIC. Is the problem xed? 11. Verify the x. Also verify that the problem job prints. Replace the Controller SIMM (see Controller PWB on page 537) or the Controller PWB (See Controller PWB on page 537) Yes Verify the x. Also verify that the problem job prints. No If there is only one NIC in the printer, go to step 11. If you have another NIC, you can try swapping NIC positions on the controller to isolate NIC vs Controller.

10.

Chapter 2. Diagnosing Problems 153

Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

12.

Chapter 2. Diagnosing Problems 154

Feed Solenoid
Table 33. Feed Solenoid
Step Actions and Questions SUSPECT COMPONENTS v Feed Solenoid (Asm-Index: 4-8, page 555) v Feeder PWB (Asm-Index: 3-1, page 553) v MCU PWB (Asm-Index: 12-8, page 575) v Cassette Guide Assembly L (Asm-Index: 3-6, page 553), including the Feeder Harness (Asm-Index: 3-12, page 553) v Tray Harness (Asm-Index: 12-17, page 575) DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 1. FEED SOLENOID POWER SUPPLY a. Remove the Controller Assembly (See page 535) b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check the voltage between P/J20-A11 <=> P/J20-B1. Is there 24VDC between P20-A11 <=> P20-B1? Go to step 3 Go to step 2 Yes No

Chapter 2. Diagnosing Problems 155

Table 33. Feed Solenoid (continued)


Step Actions and Questions CONTINUITY ON MCU PWB (Asm-Index: 12-8, page 575) 2. a. Disconnect P/J21 from the MCU PWB. b. Check for the continuity between P13-9 <=> P21-1. Is there continuity between P13-9 <=> P21-1? Does the problem appear when using Tray 2 or 3? Go to Go to step 4 Appendix G. 500-Sheet Paper Tray Option on page 661, or Appendix H. 2000-Sheet Input Drawer Option on page 703. Go to step 5 Replace the Feeder PWB (See page 420) Yes No

Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529)

3.

FEEDER PWB (Asm-Index: 3-1, page 553) a. Disconnect P/J201, P/J202 and P/J203 from the Feeder PWB (Asm-Index: 3-1, page 553). 4. b. Check for the continuity between P201 <=> P202 <=> P203 below: v P201-A1 <=> P202-A1 <=> P203-8 v P201-A8 <=> P203-9 Is the continuity on wires above between P201 <=> P202 <=> P203? PICK UP SOLENOID (Asm-Index: 6-17, page 559) 5. a. Leave P/J203 disconnected. b. Check the resistance between J203-8 <=> J203-9. Is there approximately 120 ohms resistance between J203-8 <=> P203-9?

Go to step 7

Go to step 6

Chapter 2. Diagnosing Problems 156

Table 33. Feed Solenoid (continued)


Step Actions and Questions FEEDER HARNESS (Asm-Index: 3-12, page 553) 6. a. Leave P/J203 disconnected and disconnect P/J204 from the Feed Solenoid (Asm-Index: 4-8, page 555). b. Check for the continuity on wires between J203-8 <=> J204-2 and J203-9 <=> J204-1. Is there continuity on both wires? TRAY HARNESS (Asm-Index: 12-17, page 575) a. Leave P/J20 disconnected. b. Check for the continuity on wires between J20 <=> P201 of the Tray Harness below: v J20-A10 <=> J201-A1 v J20-A4 <=> J201-A8 Is there continuity on wires above between J20 <=> P201? Go to step 8 Replace the Tray Harness Yes No

Replace the Feed Replace the Solenoid (See Feeder Harness page 446)

7.

Chapter 2. Diagnosing Problems 157

Table 33. Feed Solenoid (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. FEEDER PWB (Asm-Index: 3-1, page 553) a. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check the voltage between P203-8 <=> P/J20-B1 and P203-9 <=> P/J20-B1. Is there 24VDC between P203-8 <=> P/J20-B1 and P203-9 <=> P/J20-B1? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Actions and Questions Yes No

Replace the MCU Replace the PWB (See page Feeder PWB (See 526 or 529) page 420)

8.

9.

Chapter 2. Diagnosing Problems 158

HVPS
Table 34. HVPS
Step Actions and Questions SUSPECT COMPONENTS v HVPS (Asm-Index: 12-11, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v HVPS Harness (Asm-Index: 12-15, page 575) v EP Cartridge (Asm-Index: 11-40, page 572) v High Harness Assembly (Asm-Index: 6-5, page 559) CRU GUIDE ASSEMBLY L POWER SUPPLY a. Ensure that an EP Cartridge is installed. b. Inspect Spring contact on the CRU Guide Assembly L and the plate terminals on the EP Cartridge. Are the Spring contacting the plate terminals properly? CRU GUIDE ASSEMBLY L POWER SUPPLY a. Remove the HVPS (See page 532) while performing next step. 2. b. Inspect the Spring contact on the CRU Guide Assembly L and the HVPS during the removal of the HVPS. Does the Spring contact the HVPS properly? Go to step 3 Replace the CRU Guide Assembly L (See page 506). Go to step 2 Replace the CRU Guide Assembly L (See page 506) Yes No

1.

Chapter 2. Diagnosing Problems 159

Table 34. HVPS (continued)


Step Actions and Questions CRU GUIDE ASSEMBLY R METAL GROUNDING PLATE a. Remove the EP Cartridge (Asm-Index: 11-40, page 572). 3. b. Inspect the Metal Grounding Plate on the rear end of the CRU Guide Assembly R (Asm-Index: 11-31, page 572). Is the Metal Grounding Plate intact, free of contamination, deformation or damage? HVPS HARNESS ASSEMBLY (Asm-Index: 6-5, page 559) a. Remove the Controller Assembly (See page 535). b. Disconnect P/J15 and P/J151 from the MCU PWB and HVPS. c. Check for the continuity between J15 <=> J155 as below: v J15-1 <=> J151-13 v J15-8 <=> J151-6 v J15-2 <=> J151-12 v J15-9 <=> J151-5 v J15-3 <=> J151-11 v J15-10 <=> J151-4 v J15-4 <=> J151-10 v J15-11 <=> J151-3 v J15-5 <=> J151-9 v J15-12 <=> J151-2 v J15-6 <=> J151-8 v J15-13 <=> J151-1 v J15-7 <=> J151-7 Is there continuity between J15 <=> J155? Go to step 5 Replace the HVPS Harness Yes Go to step 4 No Replace the CRU Guide Assembly R (See page 510)

4.

Chapter 2. Diagnosing Problems 160

Table 34. HVPS (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 5. 24VDC a. Switch ON the Main Power. b. Check the voltage between P15-1 and the Printer Frame. Is the voltage between P15-1 and the Printer Frame 24VDC? MCU PWB (Asm-Index: 12-8, page 575) 6. a. Switch OFF the Main Power. b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check for the continuity between P21-1 <=> P15-1. Is there continuity between P21-1 <=> P15-1? Replace the MCU PWB (See page 526 or 529) 7. Does the problem still appear? Replace the HVPS (See page 532) 8. Does the problem still appear? Go to step 9 Go to step 8 Verify the x. Also verify that the problem job prints. Verify the x. Also verify that the problem job prints. Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529) Actions and Questions Yes Go to step 7 No Go to step 6

Chapter 2. Diagnosing Problems 161

Table 34. HVPS (continued)


Step Actions and Questions Yes No Replace the wires that do not have continuity (DTS or TR) that are contained in the High Harness Assembly (See page 468 for the removal procedure)

9.

DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page Call technical 559) support (see Appendix D. a. Remove the Transport Chute Assembly (See page 468) Technical b. Disconnect the DTS and TR Plugs from the HVPS (Asm-Index: 12-11, Support on page 575) and from the Transport Chute Assembly. page 602). c. Check for the continuity between both ends of the DTS and TR wires. Is there continuity through the DTS and TR wires? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation)

10.

If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

Chapter 2. Diagnosing Problems 162

LVPS
Table 35. LVPS
Step Actions and Questions SUSPECT COMPONENTS v LVPS Assembly (Asm-Index: 12-4, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) LVPS ASSEMBLY (Asm-Index: 12-4, page 575) 1. a. Disconnect P/J121 and P/J126. b. Switch ON the Main Power. c. Check the voltage between P121-5 <=> P121-4 and P126-1 <=> P126-2. Is there 5VDC between P121-5 <=> P121-4, and P126-1 <=> P126-2? LVPS HARNESS (Asm-Index: 12-14, page 575) a. Switch OFF the Main Power. b. Disconnect P/J11. c. Check for the continuity between J11 <=> J121 as below: v J11-1 <=> J121-6 v J11-2 <=> J121-5 (+5V) v J11-3 <=> J121-4 v J11-4 <=> J121-3 v J11-5 <=> J121-2 v J11-6 <=> J121-1 (+24V) Is there continuity between J11 <=> J121? Go to step 3 Replace the LVPS Harness Go to step 2 Replace the LVPS Assembly (See page 521) Yes No

2.

Chapter 2. Diagnosing Problems 163

Table 35. LVPS (continued)


Step AC WALL OUTLET 3. Check the AC wall outlet. Is the AC wall outlet correctly wired and grounded? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Actions and Questions Yes No

Replace the MCU Notify customer or PWB (See page their electrician. 526 or 529)

4.

Chapter 2. Diagnosing Problems 164

Paper Size Switch - 500-Sheet Paper Trays


The Autosensed Paper size indicated on the CONFIG PAGE does not match the tray size guide positions. The following table shows the combination of size switches activated (1) for each size paper.
Table 36. Paper Size Switches
Paper Size Cassette removed Universal (Non-regular size) 11x17 (Ledger) SEF A3 SEF B4 SEF Legal 14 SEF Legal 13 SEF A4 SEF Letter SEF B5 LEF Letter LEF A4 LEF Executive LEF A5 LEF Statement LEF Postcard SEF Paper Size Switch SW4 Bottom 0 1 0 0 0 0 0 0 0 1 1 1 1 1 1 0 SW3 0 0 0 0 0 1 1 1 1 1 0 0 1 1 1 1 SW2 0 0 0 1 1 0 0 1 1 0 1 1 0 1 1 1 SW1 Top 0 0 1 0 1 0 1 0 0 1 0 1 1 1 1 1

Chapter 2. Diagnosing Problems 165

Table 36. Paper Size Switches (continued)


Paper Size C5 SEF COM-10 DL SEF Monarch SEF Notes: 1. Only when the printer is switched on while pressing ONLINE (Cold Reset to LTR defaults) 2. Only when the printer is switched on while pressing CANCEL (Cold Reset to A4 defaults) Paper Size Switch SW4 Bottom 0 1 1 1 SW3 1 1 1 0 SW2 1 1 0 0 SW1 Top 1 0 0 1

Chapter 2. Diagnosing Problems 166

Table 37. Paper Size Switch


Step Actions and Questions SUSPECT COMPONENTS v Paper Cassette (Asm: 2, page 550) v Feeder PWB (Asm-Index: 3-1, page 553) v Cassette Guide Assembly (Asm-Index: 3-6, page 553) v Tray Harness (Asm-Index: 12-17, page 575) v Tray Lower1 Harness (Asm-Index: 3-2, page 553) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS 1. Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page 553). See Table 36 on page 165. Do the Size Cam states match the loaded paper size? Go to step 3 Go to step 2 Yes No

Chapter 2. Diagnosing Problems 167

Table 37. Paper Size Switch (continued)


Step Actions and Questions PAPER SIZE CAM MECHANICS Inspect the suspect components and their settings relating to the Size Cam as: v End Guide Plate (Asm-Index: 2-14, page 550) v Paper End Guide (Asm-Index: 2-15, page 550) 2. v End Guide Spring (Asm-Index: 2-16, page 550) v End Guide (Asm-Index: 2-17, page 550) v Pivot Plate (Asm-Index: 2-18, page 550) v Sector Gear (Asm-Index: 2-19, page 550) v Size Cam (Asm-Index: 2-20, page 550) Are any of these components damaged or installed incorrectly? PAPER SIZE SWITCHES The cams seem to actuate correctly, but the wrong size is reported. a. Remove the Paper from the Paper Cassette. b. Use D21 SENSOR TEST on page 261 to check the Paper Size Switches. c. Reach inside the paper feeder and press and release one Size Actuator (Asm-Index: 3-8, page 553). Press ENTER and repeat for each switch. Do the Size Switches function correctly? Possible MCU problem If the tray is an optional Tray 2 or 3, replace the option. For Tray 1, go to step 4. Yes Repair or replace the Paper Cassette as necessary No If the tray is an optional Tray 2 or 3, install a new Tray Feeder (Asm: 20, page 697), or replace the entire option. For Tray 1, replace the Cassette Guide Assembly Left (See page 426).

3.

Chapter 2. Diagnosing Problems 168

Table 37. Paper Size Switch (continued)


Step Actions and Questions PAPER SIZE SWITCH OF THE FEEDER PWB a. Remove the Feeder PWB (See page 420). 4. b. Check for the continuity between two terminals of each Paper Size Switch while you press and release it. Is there continuity through the switch when you press the Size Actuator and no continuity when you release it? 5. There is a problem with one of the Suspect Components. Yes Go to step 5 No Replace the Feeder PWB (See page 420)

6.

End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

Chapter 2. Diagnosing Problems 169

Pick Up Solenoid (Auxiliary Tray)


Note: You can test the Auxiliary Tray Pick Up Solenoid using D50 SOL TRAY A (Auxiliary Tray Feed Solenoid) on page 277.
Table 38. Pick Up Solenoid
Step Actions and Questions SUSPECT COMPONENTS v Pick Up Solenoid (Asm-Index: 6-17, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 1. PICK UP SOLENOID POWER SUPPLY a. Remove the Controller Assembly (See page 535). b. Check the voltage between P/J13-9 <=> ground. Is there 24VDC between P/J13-9 <=> ground? CONTINUITY ON MCU PWB a. Power off the printer. b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check for the continuity between P13-9 <=> P21-1. Is there continuity between P13-9 <=> P21-1? Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529) Go to step 3 Go to step 2 Yes No

2.

Chapter 2. Diagnosing Problems 170

Table 38. Pick Up Solenoid (continued)


Step Actions and Questions PICK UP SOLENOID (Asm-Index: 6-17, page 559) 3. a. Power off the printer. b. Disconnect P/J13 from the MCU PWB. c. Check the resistance between J13-9 <=> J13-10. Is there approximately 90 ohms between J13-9 <=> J13-10? HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559) 4. a. Leave P/J13 disconnected and disconnect P/J135 from the harness leading to the MSI Feed Solenoid. b. Check for the continuity on the two wires. Is there continuity on both wires? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Replace the Pick Replace the High Up Solenoid (See Harness page 477) Assembly Yes No

Replace the MCU Go to step 4 PWB (See page 526 or 529)

5.

Chapter 2. Diagnosing Problems 171

Registration Sensor
Table 39. Registration Sensor
Step Actions and Questions SUSPECT COMPONENTS v Registration Sensor (Asm-Index: 7-6, page 562) v Registration Actuator (Asm-Index: 7-7, page 562) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v LVPS Assembly (Asm-Index: 12-4, page 575) RESISTRATION SENSOR and ACTUATOR (Asm-Index: 7-6 and 7-7, page 562) a. Remove the Rear Tie Plate (part of Registration Sensor/Actuator on page 484). 1. b. Push up and then release the Registration Actuator and inspect the relative position with the detecting point of the Registration Sensor. Is the arm of the Registration Actuator away from the detecting point of the Registration Sensor when you push up the Actuator? Does the arm shield the detecting point of the Sensor when you release the Actuator? Go to step 2 Replace the Registration Sensor and/or Actuator (See page 484) Yes No

Chapter 2. Diagnosing Problems 172

Table 39. Registration Sensor (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. REGISTRATION SENSOR POWER SUPPLY a. Remove the Controller Assembly (See page 535). b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). c. Disconnect P/J13, and then check the voltage between P13-3 <=> P13-4. Is there 5VDC between P13-3 <=> P13-4? CONTINUITY ON MCU PWB a. Disconnect P/J11 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check for the continuity between P11-5 <=> P13-3. Is there continuity between P11-5 <=> P13-3? Go to LVPS on page 163 Replace the MCU PWB (See page 526 or 529) Actions and Questions Yes Go to step 4 No Go to step 3

2.

3.

Chapter 2. Diagnosing Problems 173

Table 39. Registration Sensor (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 4. POWER SUPPLY TO THE REGISTRATION PAPER DETECTOR a. Leave P/J12, P/J15 and P/J17 on the MCU PWB disconnected. b. Check the voltage between P/J13-5 <=> P/J13-4. Is there 5VDC between P/J13-5 <=> P/J13-4? DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. REGISTRATION SENSOR SIGNAL a. Leave P/J12, P/J15 and P/J17 on the MCU PWB disconnected. b. Press and release the Registration Actuator (Asm-Index: 7-7, page 562). c. Check the voltage between P/J13-5 <=> P/J13-4. Is there 0VDC between P/J13-5 <=> P/J13-4 when you press the Actuator, and 5VDC when you release it? Replace the MCU Go to step 6 PWB (See page 526 or 529) Actions and Questions Yes Go to step 5 No Replace the MCU PWB (See page 526 or 529)

5.

Chapter 2. Diagnosing Problems 174

Table 39. Registration Sensor (continued)


Step Actions and Questions HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559) 6. a. Disconnect P/J13 and P/J132. b. Check for the continuity on each wire between J13-3 <=> J132-3, J13-4 <=> J132-2, and J13-5 <=> J132-1. Is there continuity between J13 <=> J132? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

Replace the Replace the High Registration Harness Sensor (See page Assembly 484)

7.

Chapter 2. Diagnosing Problems 175

Toner Sensor
Table 40. Toner Sensor
Step Actions and Questions SUSPECT COMPONENTS v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v MCU PWB (Asm-Index: 12-8, page 575) v Toner Sensor Harness (Asm-Index: 5-17, page 557) v Toner Relay Harness (Asm-Index: 12-18, page 575) v MSI Bracket Assembly (Asm-Index: 5-7, page 557) DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 1. TONER SENSOR POWER SUPPLY a. Remove the Controller Assembly (See page 535). b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check the voltage between P/J22-1 <=> P/J22-3. Is there 24VDC between P/J22-1 <=> P/J22-3? CONTINUITY ON MCU PWB a. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check for the continuity between P22-1<=> P21-1. Is there continuity between P22-1 <=> P21-1? Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529) Go to step 3 Go to step 2 Yes No

2.

Chapter 2. Diagnosing Problems 176

Table 40. Toner Sensor (continued)


Step DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 3. TONER DETECTOR SIGNAL a. Leave P/J12, P/J15 and P/J17 on the MCU PWB disconnected. b. Check the voltage between P22-4 <=> P22-3. Is there 5VDC between P22-4 <=> P22-3? DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. TONER DETECTOR SIGNAL a. Leave P/J12, P/J15 and P/J17 disconnected. b. Press down and hold the Interlock Switch (Asm-Index: 12-1, page 575). c. Check the voltage between P22-4 <=> P22-3 while you remove and reinstall the EP Cartridge. Is there 0VDC between P22-4 <=> P22-3 when you install the EP Cartridge, and 5VDC when you remove it? Replace the MCU Go to step 5 PWB (See page 526 or 529) Actions and Questions Yes Go to step 4 No Replace the MCU PWB (See page 526 or 529)

4.

Chapter 2. Diagnosing Problems 177

Table 40. Toner Sensor (continued)


Step Actions and Questions TONER RELAY HARNESS (Asm-Index: 12-18, page 575) 5. a. Disconnect P/J22 from the MCU PWB and P/J222 from the harness leading to the Toner Sensor (Asm-Index: 5-14, page 557). b. Check for the continuity of each wire between J22 <=> J222. Is there continuity between J22 <=> J222? TONER SENSOR HARNESS (Asm-Index: 5-17, page 557) 6. Replace the Toner Replace the Toner a. Disconnect P/J221 from the Toner Sensor and leave P/J222 disconnected. Sensor Assembly Sensor Harness (See page 462) b. Check for the continuity of each wire between J221 <=> P222. Is there continuity between J221 <=> P222? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes Go to step 6 No Replace the Toner Relay Harness

7.

Chapter 2. Diagnosing Problems 178

Twinax / Coax NIC Printing Problems


Notes: 1. For Twinax NICs, ensure that the printer station address is set correctly in the TWINAX SETUP MENU (IPDS ADDR or SCS ADDR). 2. If the printer has had a cold reset, have the user ensure that all menus have been tailored to their original settings. If necessary, see an old Cong Page printout.
Table 41. Twinax/Coax NIC Printing Problems
Step 1. Actions and Questions Is the problem only with IPDS jobs? Yes Go to step 2 No Go to step 3

Print a Cong Page (see page 250). Is IPDS indicated on the Cong Page? 2.

Verify that there is enough memory for IPDS jobs. Refer to the IBM InfoPrint 20: Users Guide for memory requirements. Go to step 3. Go to step 4

Reseat the IPDS SIMM. If that does not x the problem, install a new IPDS SIMM.

Switch on the printer power. Wait for the READY message. 3. Does READY appear within 5 minutes?

Return to Chapter 1. Getting Started on page 25 with the new error code or symptom.

Chapter 2. Diagnosing Problems 179

Table 41. Twinax/Coax NIC Printing Problems (continued)


Step Actions and Questions Can you print a printer Cong Page? 4. Yes Go to step 5 No Return to Chapter 1. Getting Started on page 25 with the new error code or symptom. Go to step 10

5.

Is the Twinax or Coax NIC indicated on the printer Cong Page?

Go to step 6

6.

Can you print a NIC Cong Page from the Test button on the back of the Go to step 7 NIC? When a job is sent, does the printer operator panel indicate its arrival with a message such as TX IPDS or CX IPDS? The cabling and NIC are OK. Suspect a problem with menu settings, the IPDS SIMM, or the controller SIMM/board.

Go to step 10

Go to step 8

7.

Chapter 2. Diagnosing Problems 180

Table 41. Twinax/Coax NIC Printing Problems (continued)


Step Actions and Questions Check the green LED (labelled CU) on the back of the NIC. Is the green LED On or Blinking? Yes No

8.

The NIC is Go to step 9 receiving polls from the system. Suspect a job or conguration problem. Refer the System Administrator to the IBM Network Printers: Twinax and Coax Conguration Guide or Tech Support. Note: If the Share light is also on when the printer is READY, install a new NIC.

Chapter 2. Diagnosing Problems 181

Table 41. Twinax/Coax NIC Printing Problems (continued)


Step Actions and Questions The NIC can communicate with the controller, but the system cannot communicate with the NIC. Check the cable connection at the back of the Twinax of Coax NIC. Is the connection OK? Yes No

9.

There is probably Replace the NIC a network cabling problem or a conguration problem. Refer the System Administrator to the IBM Network Printers: Twinax and Coax Conguration Guide or Tech Support (see Appendix D. Technical Support on page 602). Verify the x. Also verify that the problem job prints. If there is only one NIC in the printer, go to step 11. If you have another NIC, you can try swapping NIC positions on the controller to isolate NIC vs Controller.

10.

There is a problem with the NIC or Controller v Power off. v Reseat the NIC v Power on and wait. Is the problem xed?

Chapter 2. Diagnosing Problems 182

Table 41. Twinax/Coax NIC Printing Problems (continued)


Step Actions and Questions Install a new NIC (See Network Interface Card on page 541) Is the problem xed? 11. Yes Verify the x. Also verify that the problem job prints. No Replace the Controller SIMM (See Controller PWB SIMM on page 539)or the Controller PWB (See Controller PWB on page 537)

12.

End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

Chapter 2. Diagnosing Problems 183

Print Quality
Background
PROBLEM: There is toner contamination on all or part of the page. The contamination appears as a light gray dusting.

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Chapter 2. Diagnosing Problems 184

Table 42. Background


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v Fuser Assembly (Asm-Index: 8-1, page 564) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? PRINT DENSITY a. Find the white volume knob near the left end of the EP cartridge. Ensure that it is at the nominal position (centered between +1 and -1). b. Adjust CONFIG MENU/DENSITY to a lower setting. c. Run a Test Print. d. If necessary, try adjusting the knob clockwise to a higher position. Is the background gone? 2. EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Is the background gone? Verify the x. Also Go to step 3 verify that the problem job prints. Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 185

Table 42. Background (continued)


Step Actions and Questions IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF printer power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Are the undeveloped areas of the drum clean and without background? TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559) GROUND a. Remove the EP Cartridge (Asm-Index: 11-40, page 572). 4. b. Check for the continuity, from the front opening, between metal parts of the Transport Chute Assembly and the Printer Frame. Is the Transport Chute Assembly grounded? FUSER ASSEMBLY (Asm-Index: 8-1, page 564) GROUND 5. a. Open the Fuser Cover Assembly. b. Check for the continuity between the screw located at the back side of the Fuser Assembly and the Printer Frame. Is the Fuser Assembly grounded? Go to the last step of this diagnostic. Go to step 5 Remove and reinstall the Transport Chute Assembly (See page 468), so that it is grounded properly. Remove and reinstall the Fuser Assembly (See page 487), so that it is grounded properly. Yes Go to step 4 No Go to HVPS on page 159

3.

Chapter 2. Diagnosing Problems 186

Table 42. Background (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

6.

Chapter 2. Diagnosing Problems 187

Black Prints
PROBLEM: The entire print is black. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.

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Chapter 2. Diagnosing Problems 188

Table 43. Black Prints


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v HVPS Harness (Asm-Index: 12-15, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Is the print normal? HVPS (Asm-Index: 12-11, page 575) 2. a. Shield the entire window of the ROS Assembly (Asm-Index: 11-20, page 572). b. Run a Test Print. Is the print black? ROS ASSEMBLY (Asm-Index: 11-20, page 572) 3. a. Shield half of the window of the ROS Assembly. b. Run a Test Print. Is the print half white and half black? Go to the last step of this diagnostic. Replace the MCU PWB (See page 526 or 529) Go to HVPS on page 159 Go to step 3 Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 189

Table 43. Black Prints (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

4.

Chapter 2. Diagnosing Problems 190

Blank Prints
PROBLEM: The entire print is blank. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.

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Chapter 2. Diagnosing Problems 191

Table 44. Blank Prints


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v Fuser Assembly (Asm-Index: 8-1, page 564) v LVPS Assembly (Asm-Index: 12-4, page 575) v HVPS Harness (Asm-Index: 12-15, page 575) v Pop Up Frame (Asm-Index: 11-1, page 572) v CRU Latch (Asm-Index: 11-13, page 572) v CRU Latch Spring (Asm-Index: 11-14, page 572) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? EP CARTRIDGE a. Install new EP Cartridge. b. Reprint the problem image. Is there a normal image on the paper? Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 192

Table 44. Blank Prints (continued)


Step Actions and Questions DRUM GROUND a. Remove the EP Cartridge. b. Inspect the metal grounding plate on the rear end of the CRU Guide Assembly R (Asm-Index: 11-30, page 572). Is the metal grounding plate intact, not contaminated and not deformed? Yes Go to step 3 No Reform or clean the Metal Grounding Plate, so it makes better contact with the drum shaft, or replace the CRU Guide Assembly R (See page 510). Replace the CRU Guide Assembly R (See page 510)

2.

GROUND OF THE METAL GROUNDING PLATE 3. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Grounding Plate and the printer frame? 4. BTR ASSEMBLY (Asm-Index: 6-1, page 559) Is the BTR intact, not contaminated? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed, with sharp, black, easily read areas?

Go to step 4

Go to step 5

Replace BTR Assembly (See page 466) Go to HVPS on page 159

Go to step 6

5.

Chapter 2. Diagnosing Problems 193

Table 44. Blank Prints (continued)


Step Actions and Questions IMAGE TRANSFER PROCESS 6. Inspect the toner image on the drum immediately after the transfer area (BTR). Was any of the toner image on the drum transferred to the paper? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

Problem with the Go to HVPS on BTR Assembly or page 159 wiring

7.

Chapter 2. Diagnosing Problems 194

Black Horizontal Stripes


PROBLEM: The print contains black horizontal stripes of varying widths. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with black horizontal stripes of varying widths may print. To diagnose this problem, see Operator Panel, Controller, and Power Problems on page 135.

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Chapter 2. Diagnosing Problems 195

Damaged Print
PROBLEM: The printed page comes out of the printer either wrinkled, creased, or torn.

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Chapter 2. Diagnosing Problems 196

Table 45. Damaged Print


Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564) v MCU PWB (Asm-Index: 12-8, page 575) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v EP Cartridge (Asm-Index: 11-40, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Pick Up Roll (Asm-Index: 6-8, page 559) v Retard Pad Assembly (Asm-Index: 6-18, page 559) v Rear Roll Assembly (Asm-Index: 4-11, page 555) v Turn Roll Assembly (Asm-Index: 4-10, page 555) v Turn Chute Assembly (Asm-Index: 3-5, page 553) v Turn In Chute (Asm-Index: 3-4, page 553) v Feed Roll (Asm-Index: 4-1, page 555) v Paper Cassette (Asm: 2, page 550) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? PAPER FEED 1. Observe paper feed. Is the paper fed crooked? Go to Skewed Image on page 212 Go to step 2 Yes No

Chapter 2. Diagnosing Problems 197

Table 45. Damaged Print (continued)


Step Actions and Questions PAPER CONDITIONS a. Replace paper with fresh, dry standard paper. b. Run a Test Print. Is the paper still damaged? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567) and PRESSURE ROLL (Asm-Index: 9-15, page 567) 3. a. Open the Pop Up Unit. b. Open the Fuser Cover Assembly and the Fuser Rear Assembly (Asm-Index: 8-10, page 564). c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manually and inspect the Heat Roll and the Pressure Roll. Are the Heat Roll and the Pressure Roll free of scratches and contamination? PAPER PATH 4. Inspect the paper path between the feed tray and the exit tray for contamination or obstructions. Is the paper path free of obstructions? Go to step 5 Remove obstructions or contamination from the paper path. Go to step 4 Clean or replace the Fuser Assembly (See page 487) Yes Go to step 3 No Verify the x. Also verify that the problem job prints.

2.

Chapter 2. Diagnosing Problems 198

Table 45. Damaged Print (continued)


Step PAPER PATH ROLLS 5. Inspect all of the rolls along the paper path between the feed tray and the exit tray for contamination, wear or damage. Are the paper path rolls free of contamination, wear, or damage? Actions and Questions Yes Go to step 6 No Replace the damaged or worn roll. (See Chapter 6. Removal Procedures, Adjustments on page 394) Verify the x. Also verify that the problem job prints.

6.

EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Is the print still damaged? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation)

Go to step 7

7.

If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).

Chapter 2. Diagnosing Problems 199

Fusing, Not Fused or Partially Fused Image


PROBLEM: The printed image is not fully fused to the paper. The image easily rubs off.

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Table 46. Fusing, Not Fused or Partially Fused Image


Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? PAPER CONDITIONS a. Replace the paper with fresh, dry standard paper. b. Reprint the problem image. Is the problem still present? Go to step 2 Verify the x. Also verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 200

Table 46. Fusing, Not Fused or Partially Fused Image (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567) and PRESSURE ROLL (Asm-Index: 9-15, page 567) 2. a. Open the Pop Up Unit. b. Remove the Fuser Assembly (See page 487). c. Inspect the Heat Roll and Pressure Roll rotating the Exit Gear (Asm-Index: 9-29, page 567) manually. Are the Heat Roll and the Pressure Roll free of scratches and contamination? FUSER ASSEMBLY (Asm-Index: 8-1, page 564) 3. a. Rotate the Exit Gear Manually. b. Inspect the contact between the Heat Roll and the Pressure Roll along the rotation. Are the Heat Roll and the Pressure Roll contacting each other uniformly? Go to step 4 Replace the Fuser Assembly (See page 487) Yes Reinstall the Fuser Assembly (See page 487). Go to step 3. No Clean or replace the Fuser Assembly (See page 487)

Chapter 2. Diagnosing Problems 201

Table 46. Fusing, Not Fused or Partially Fused Image (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

4.

Chapter 2. Diagnosing Problems 202

Light (Undertoned) Prints


PROBLEM: The overall image density is too light.

hc2m201F

Chapter 2. Diagnosing Problems 203

Table 47. Light (Undertoned) Prints


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v HVPS Harness (Asm-Index: 11-15, page 572) v Fuser Assembly (Asm-Index: 8-1, page 564) v LVPS Assembly (Asm-Index: 12-4, page 575) v CRU Latch (Asm-Index: 11-13, page 572) v CRU Latch Spring (Asm-Index: 11-14, page 572) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? PRINT DENSITY a. Find the white volume knob near the left end of the EP cartridge. Ensure that it is at the nominal position (centered between +1 and -1). b. Adjust the CONFIG MENU/DENSITY setting as needed. c. Reprint the problem image. Is the image density normal? Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 204

Table 47. Light (Undertoned) Prints (continued)


Step 2. PAPER CONDITIONS a. Load fresh, dry paper. b. Run a Test Print. Is the image density normal? 3. EP CARTRIDGE a. Install a new EP Cartridge. b. Reprint the problem image. Is the image density normal? DRUM GROUND a. Remove the EP Cartridge (Asm-Index: 11-40, page 572). 4. b. Inspect the two Metal Grounding Springs on the rear end of the CRU Guide Assembly L (Asm-Index: 11-30, page 572). They should both have the same shape. Are the metal grounding springs intact, not contaminated, and not deformed? Go to step 5 Reform or clean the metal grounding plate, so it makes better contact with the drum shaft, or replace the CRU Guide Assembly R (See page 510). Replace the CRU Guide Assembly R (See page 510) Verify the x. Also Go to step 4 verify that the problem job prints. Actions and Questions Yes No

Verify the x. Also Go to step 3 verify that the problem job prints.

CONTINUITY OF THE METAL GROUNDING PLATE 5. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Plate Grounding Plate and the printer frame?

Go to step 6

Chapter 2. Diagnosing Problems 205

Table 47. Light (Undertoned) Prints (continued)


Step LASER BEAM PATH 6. Inspect laser beam path between the ROS Assembly (Asm-Index: 11-20, page 572) and the Drum. Is the laser beam path free of obstructions? 7. BTR ASSEMBLY (Asm-Index: 6-1, page 559) Is the BTR intact and not contaminated? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF the printer power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed with sharp, black, easily read areas? IMAGE TRANSFER PROCESS 9. Inspect the toner image on the drum immediately after the transfer area (BTR). Is the toner image on the drum transferred completely to the paper? Go to step 10 Go to HVPS on page 159 Go to step 9 Go to step 8 Actions and Questions Yes Go to step 7 No Clean the mirror and remove any obstructions from the laser beam path. Replace the BTR Assembly (See page 466) Go to HVPS on page 159

8.

Chapter 2. Diagnosing Problems 206

Table 47. Light (Undertoned) Prints (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

10.

Chapter 2. Diagnosing Problems 207

Residual Image
PROBLEM: There are ghost images on the page. The images may be either ghosts of the previous page or parts of the page being printed.

hc2m210F

Chapter 2. Diagnosing Problems 208

Table 48. Residual Image


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v Fuser Assembly (Asm-Index: 8-1, page 564) v Heat Roll (Asm-Index: 9-10, page 567) v Pressure Roll (Asm-Index: 9-15, page 567) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? REPETITIVE PRINTING 1. Inspect the residual images. Was the customer printing numerous copies of the same image? 2. PAPER CONDITION a. Replace paper with fresh, dry standard paper. b. Reprint the problem image. Do residual images still appear? Go to step 3 Verify the x. Also verify that the problem job prints. Go to step 2 Go to step 3 Yes No

Chapter 2. Diagnosing Problems 209

Table 48. Residual Image (continued)


Step EP CARTRIDGE 3. Install a new EP Cartridge. Do residual images still appear? BTR ASSEMBLY 4. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. FUSER ASSEMBLY a. Open the Pop Up Unit. b. Remove the Fuser Assembly (See page 487). c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manually and inspect the Heat Roll (Asm-Index: 9-10, page 567) and Pressure Roll (Asm-Index: 9-15, page 567). Are the Heat Roll and the Pressure Roll free of scratches and contamination? Reinstall the Fuser Assembly. Go to the step 6. Clean or replace the Fuser Assembly (See page 487) Go to step 5 Actions and Questions Yes Go to step 4 No Verify the x. Also verify that the problem job prints. Replace the BTR Assembly (See page 466)

5.

Chapter 2. Diagnosing Problems 210

Table 48. Residual Image (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

6.

Chapter 2. Diagnosing Problems 211

Skewed Image
PROBLEM: The printed image is not parallel with the sides of the page.

hc2m212F

Chapter 2. Diagnosing Problems 212

Table 49. Skewed Image


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v Fuser Assembly (Asm-Index: 8-1, page 564) v Pick Up Roll (Asm-Index: 6-9, page 559) v Retard Pad Assembly (Asm-Index: 6-18, page 559) v Front Bottom Tray (Asm-Index: 5-5, page 557) v Rear Roll Assembly (Asm-Index: 4-11, page 555) v Turn Roll Assembly (Asm-Index: 4-10, page 555) v Turn Chute Assembly (Asm-Index: 3-5, page 553) v Turn In Chute (Asm-Index: 3-4, page 553) v Feed Roll (Asm-Index: 4-1, page 555) v Paper Cassette (Asm: 2, page 550) v ROS Assembly (Asm-Index: 11-20, page 572) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? Yes No

Chapter 2. Diagnosing Problems 213

Table 49. Skewed Image (continued)


Step Actions and Questions PAPER FEED a. Remove the Paper Cassette (Asm: 2, page 550). b. c. d. e. Verify that the paper guides are adjusted to match the paper size. Reload the paper correctly in the Paper Cassette. Reinstall the Paper Cassette correctly. Open the Turn Chute Assembly (Asm-Index: 3-5, page 553) and ensure that the Bottom Plate Assembly (Asm-Index: 2-10, page 550) is positioned correctly. Yes Go to step 2 No Verify the x. Also verify that the problem job prints.

1.

f. Reprint the problem image. Is the problem still present? PAPER PATH 2. Inspect the paper path between the feed tray and the exit tray for contamination or obstructions. Is the paper path free of obstructions? PAPER PATH ROLLS Go to step 4 a. Inspect all of the rolls along the paper path, between the feed tray and the exit tray, for contamination, wear, or damage. b. Ensure that the pinch rolls turn freely and that the spring pressure is even. Are the paper path rolls free of contamination, wear, or damage? Go to step 3 Remove obstructions or contamination from the paper path. Replace the damaged or worn roll. (See Chapter 6. Removal Procedures, Adjustments on page 394)

3.

Chapter 2. Diagnosing Problems 214

Table 49. Skewed Image (continued)


Step Actions and Questions EP CARTRIDGE a. Install a new EP Cartridge. b. Reprint the problem image. Is the image still skewed? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes Go to step 5 No Verify the x. Also verify that the problem job prints.

4.

5.

Chapter 2. Diagnosing Problems 215

Spots
PROBLEM: There are spots of toner randomly scattered across the page.

hc2m209F

Table 50. Spots


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? Yes No

Chapter 2. Diagnosing Problems 216

Table 50. Spots (continued)


Step Actions and Questions EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Are the spots gone? BTR ASSEMBLY 2. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF printer power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed, with sharp, black easily read areas and no spots? Replace the Fuser Assembly (See page 487) Go to HVPS on page 159 Go to step 3 Replace the BTR Assembly (See page 466) Yes No

1.

Verify the x. Also Go to step 2 verify that the problem job prints.

3.

Chapter 2. Diagnosing Problems 217

Table 50. Spots (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

4.

Chapter 2. Diagnosing Problems 218

Streaks, Horizontal
PROBLEM: There are black lines running horizontally across the page. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.

hc2m207F

Chapter 2. Diagnosing Problems 219

Table 51. Streaks, Horizontal


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? EP CARTRIDGE a. Install a new EP Cartridge. b. Reprint the problem image. Are the horizontal streaks gone? DRIVE TRANSMISSION 2. Perform 53 ERROR CALL FOR SERVICE on page 114 and x the problems if any. Is the rotation of the Main Motor (Asm-Index: 10-6, page 570) transmitted to all the rolls? Go to step 3 Follow the instructions in 53 ERROR CALL FOR SERVICE on page 114. Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 220

Table 51. Streaks, Horizontal (continued)


Step Actions and Questions DRUM GROUND a. Remove the EP Cartridge. b. Inspect the metal grounding plate on the rear end of the CRU Guide Assembly R (Asm-Index: 11-31, page 572). Is the metal grounding plate intact, not contaminated and not deformed? Yes Go to step 4 No Reform or clean the metal grounding plate, so it makes better contact with the drum shaft, or replace the CRU Guide Assembly R (See page 510). Replace the CRU Guide Assembly R (See page 510)

3.

CONTINUITY OF THE METAL GROUNDING PLATE 4. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Grounding Plate and the Printer Frame? BTR ASSEMBLY (Asm-Index: 6-1, page 559) 5. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF printer power halfway through print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the Drum just before the transfer area (BTR). Is the image on the Drum completely developed; with sharp, black, easily read areas and no horizontal streaks?

Go to step 5

Go to step 6

Replace the BTR Assembly (See page 466) Go to HVPS on page 159

Go to step 7

6.

Chapter 2. Diagnosing Problems 221

Table 51. Streaks, Horizontal (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. 7. IMAGE TRANSFER PROCESS Inspect the toner image on the Drum immediately after the transfer area (BTR). Was the toner image on the Drum transferred completely to the paper along with horizontal streaks? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes Replace the Fuser Assembly (See page 487) No Replace the BTR Assembly (See page 466)

8.

Chapter 2. Diagnosing Problems 222

Streaks, Vertical
PROBLEM: There are black lines running vertically along the page. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.

hc2m206F

Chapter 2. Diagnosing Problems 223

Table 52. Streaks, Vertical


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v MCU PWB (Asm-Index: 12-8, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Are the vertical streaks gone? LASER BEAM PATH 2. Inspect the laser beam path between the ROS Assembly and the Drum. Is the laser beam path free of obstructions? BTR ASSEMBLY 3. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? Go to step 4 Go to step 3 Remove any obstructions from the laser beam path. Replace the BTR Assembly (See page 466) Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 224

Table 52. Streaks, Vertical (continued)


Step PAPER PATH 4. Inspect the paper path, between feed and exit, for contamination or obstructions. Is the paper path free of obstructions? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567) and PRESSURE ROLL (Asm-Index: 9-15, page 567) 5. a. Open the Pop Up Unit. b. Open the Fuser Cover Assembly and the Fuser Rear Assembly (Asm-Index: 8-10, page 564). c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manually and inspect the Heat Roll and the Pressure Roll. Are the Heat Roll and the Pressure Roll free of scratches and contamination? Go to step 6 Actions and Questions Yes Go to step 5 No Remove obstructions or contamination from the paper path Replace the Fuser Assembly (See page 487)

Chapter 2. Diagnosing Problems 225

Table 52. Streaks, Vertical (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

6.

Chapter 2. Diagnosing Problems 226

Unusual Patterns
PROBLEM: Light gray background, with large areas covered with random dark spots. This is usually caused by charging problems during printing.

hc2m216F

Table 53. Unusual Patterns


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v BTR Assembly (Asm-Index: 6-1, page 559), unseated or bad v Dirty or bent contacts on the EP Cartridge or BTR Assembly v HVPS (Asm-Index: 12-11, page 575) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? Yes No

Chapter 2. Diagnosing Problems 227

Table 53. Unusual Patterns (continued)


Step Actions and Questions v Exchange the suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

Chapter 2. Diagnosing Problems 228

Voids
PROBLEM: There are areas of the image that are extremely light or missing. These missing areas form localized spots to small areas of the page.

hc2m208F

Table 54. Voids


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? Yes No

Chapter 2. Diagnosing Problems 229

Table 54. Voids (continued)


Step Actions and Questions PAPER CONDITIONS a. Load fresh, dry standard paper b. Reprint the problem image. Is the problem still present? EP CARTRIDGE a. Install a new EP Cartridge. b. Reprint the problem image. 2. Note: If the new EP cartridge xes the problem, the problem may have been caused by toner clumping in the old EP cartridge. This sometimes happens in hot and humid environments. Shaking the old EP cartridge to break up the toner clumps may x the problem. Use caution when shaking the EP cartridge so that toner is not expelled. Is the problem still present? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF printer power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed; with sharp, black easily read areas and no spot deletions? IMAGE TRANSFER PROCESS 4. Inspect the toner image on the drum immediately after the transfer area (BTR). Is the toner image on the drum transferred completely to the paper? Replace the Fuser Assembly (See page 487) Replace the BTR Assembly (See page 466) Go to step 4 Go to HVPS on page 159 Go to step 3 Verify the x. Also verify that the problem job prints. Yes Go to step 2 No Verify the x. Also verify that the problem job prints.

1.

3.

Chapter 2. Diagnosing Problems 230

Table 54. Voids (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

5.

Chapter 2. Diagnosing Problems 231

Voids, Horizontal
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands that run horizontally across the page, parallel with the direction of paper travel.

hc2m205F

Chapter 2. Diagnosing Problems 232

Table 55. Voids, Horizontal


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v Fuser Assembly (Asm-Index: 8-1, page 564) v Main Gear Assembly (Asm-Index: 10-10, page 570) v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570) v Registration Clutch Assembly (Asm-Index: 10-9, page 570) v Rear Roll Assembly (Asm-Index: 4-11, page 555) v Turn Roll Assembly (Asm-Index: 4-10, page 555) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? PAPER CONDITIONS a. Load fresh, dry standard paper. b. Reprint the problem image. Does the problem appear? Go to step 2 Verify the x. Also verify that the problem job prints. Yes No

1.

Chapter 2. Diagnosing Problems 233

Table 55. Voids, Horizontal (continued)


Step Actions and Questions MAIN MOTOR (Asm-Index: 10-6, page 570) and DRIVE TRANSMISSION 2. a. Refer to 53 ERROR CALL FOR SERVICE on page 114 for causes of possible motor problems. b. Reprint the problem image. Does the problem appear? EP CARTRIDGE 3. Install a new EP Cartridge. Are the horizontal band deletions gone? BTR ASSEMBLY (Asm-Index: 6-1, page 559) 4. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? IMAGE DEVELOPMENT PROCESS a. Generate a print and switch OFF printer power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed, with sharp, black, easily read areas and no horizontal band deletions? Go to step 6 Go to HVPS on page 159 Verify the x. Also Go to step 4 verify that the problem job prints. Go to step 5 Replace the BTR Assembly (See page 466) Yes Go to step 3 No Verify the x. Also verify that the problem job prints.

5.

Chapter 2. Diagnosing Problems 234

Table 55. Voids, Horizontal (continued)


Step Actions and Questions CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. 6. IMAGE TRANSFER PROCESS Inspect the toner image on the drum immediately after the transfer area (BTR). Was the toner image on the drum transferred completely to the paper? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes Replace the Fuser Assembly (See page 487). Go to step 7. No Go to HVPS on page 159

7.

Chapter 2. Diagnosing Problems 235

Voids, Vertical
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands that run vertically along, in the direction of paper travel.

hc2m204F

Table 56. Voids, Vertical


Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v BTR Assembly (Asm-Index: 6-1, page 559) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v ROS Assembly (Asm-Index: 11-20, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v Fuser Assembly (Asm-Index: 8-1, page 564) Before starting, inspect the printer paper path. Is it clear of foreign matter such as staples, paper clips and paper scraps? Yes No

Chapter 2. Diagnosing Problems 236

Table 56. Voids, Vertical (continued)


Step Actions and Questions PAPER CONDITIONS a. Load fresh, dry standard paper. b. Reprint the problem image. Is the problem still present? EP CARTRIDGE (Asm-Index: 11-40, page 572) 2. a. Install a new EP Cartridge. b. Reprint the problem image. Is the problem still present? LASER BEAM PATH 3. Inspect the laser beam path between the ROS Assembly and the Drum. Is the laser beam path free of obstructions? PAPER PATH 4. Inspect the paper path, between feed and exit, for contamination or obstructions. Is the paper path free of obstructions? BTR ASSEMBLY (Asm-Index: 6-1, page 559) 5. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? Replace the Fuser Assembly (See page 487) Go to step 5 Go to step 4 Remove any obstructions from the laser beam path. Remove obstructions or contamination from the paper path. Replace the BTR Assembly (See page 466) Go to step 3 Verify the x. Also verify that the problem job prints. Yes Go to step 2 No Verify the x. Also verify that the problem job prints.

1.

Chapter 2. Diagnosing Problems 237

Table 56. Voids, Vertical (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

6.

Chapter 2. Diagnosing Problems 238

Status Messages
Printer status messages are listed alphabetically. COLD RESET A4 Meaning: The printer is powering up and resetting all menu values to the factory defaults. The A4 paper group is the default. Action: None required; however, restore any unique settings for the printer (such as the default tray). COLD RESET LTR Meaning: The printer is powering up and resetting all menu values to the factory defaults. The LTR paper group is the default. Action: None required; however, restore any unique settings for the printer (such as the default tray). CONTEXT SAVE ADJUSTED Meaning: The printer is congured to use the context saving option (PCL SAVE and PS SAVE under the Memcong Menu); however, due to a conguration change, the printer no longer has enough memory to support context saving. Action: Press Continue. To restore context saving, have the customer add more memory to the printer. CONTEXT SAVE CHANGE Meaning: The values for the PCL SAVE or PS SAVE items under the Memcong Menu have been changed. Action: Press the Continue key to accept the new values and continue printing. DSK FMT RESTART Meaning: The printer is restarting to include the hard drive in its conguration. Action: None required.

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+ FORMAT DISK/- IGNORE DISK Meaning: You are powering up with an unformatted hard drive, or you selected the FORMAT DISK action on the Test Menu. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to continue as if there were no hard drive installed. FLUSHING... Meaning: The printer is canceling a PCL5e or PostScript job. Action: None required. FORMATTING Meaning: The printer is formatting the hard disk drive. Action: None required. F/W xxxxxxx Meaning: Firmware error (xxxxxxx can be any alphanumeric value). Action: Power the printer off, wait ten seconds, and power the printer back on. If problems persist, call for technical support. Note: When rmware errors occur, the printer might also print an error page. If the printer does print an error page, save it so you can tell technical support. I/O INITIALIZING Meaning: The network interface card is initializing. Action: Normally none. If the message remains on the display for more than 5 minutes and nothing prints, go to Ethernet / Token-Ring NIC Printing Problems on page 150 or Twinax / Coax NIC Printing Problems on page 179. Note: If more than one Network Interface Card is installed, remove them one at a time to determine which card is causing the problem.

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IBM INFOPRINT 20 Meaning: The printer power has just been switched on. Action: Normally none. If the message remains on the display and nothing prints, wait three minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to Operator Panel, Controller, and Power Problems on page 135. - IGNORE DISK/+ FORMAT DISK Meaning: You are powering up with an unformatted hard drive, or you selected the FORMAT DISK action on the Test Menu. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to continue as if there were no hard drive installed. IPDS COAX Meaning: The printer is receiving IPDS data through the coax interface. Action: None required. IPDS ETHERNET Meaning: The printer is receiving IPDS data through the Ethernet interface. Action: None required. IPDS TOKEN-RING Meaning: The printer is receiving IPDS data through the token-ring interface. Action: None required. IPDS TWINAX Meaning: The printer is receiving IPDS data through the twinax interface. Action: None required. JOB QUEUED Meaning: An informational page is queued for printing. Action: If the online indicator is off, press the Online key.
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KEY NOT VALID Meaning: You pressed a key that is not valid. Action: Press another key. In some instances, you may need to press the Online key to use other keys such as the Menu key. MEMCONFIG CHANGE Meaning: You changed a value on the Memory Conguration (Memcong) Menu. Action: Press the Continue key to reboot the printer so the new value can take effect. MEMCONFIG CHANGE 1200 DPI UNAVAIL Meaning: You turned on context saving (PCL SAVE or PS SAVE) on the Memory Conguration (Memcong) Menu. 1200 dpi emulation is no longer available because there is not enough memory. Action: Press the Continue key to reboot the printer so the new value can take effect. To enable 1200 DPI emulation, Have the customer add more memory or turn context saving off. MENU LOCKED Meaning: The system administrator has locked the menu. You can view menu settings but you cannot change them. Action: None required. MRT COMPRESSION Meaning: The printer is compressing the page image it is printing because it does not have enough memory to print the page without compression. Action: None required. NEW VALUES AT NEXT BOUNDARY Meaning: You have taken the printer offline while a job was printing to change a menu value. The new value might not take effect until the next job boundary. Different data streams, in particular SCS, dene job boundaries in different ways, so it may take a while for the new value to take effect. Action: None required. If problems occur, make sure you take the printer offline to change menu values only when no jobs are printing (the printer is in READY state).
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NONIPDS COAX Meaning: The printer is receiving SCS or DSC/DSE data through the coax interface. Action: None required. NONIPDS TWINAX Meaning: The printer is receiving SCS data through the twinax interface. Action: None required. OFFLINE Meaning: The printer is offline. Action: Press the Online key to make the printer active. ONLINE HEX PRT Meaning: The printer is performing a hexadecimal dump. Action: None required. PAGES:nnnn Meaning: This is a response to the PAGE COUNT item on the Machine Info Menu, where nnnn is the number of pages the printer has printed. Action: None required. PCL ETHERNET Meaning: The printer is receiving PCL5e data through the Ethernet interface. Action: None required. PCL PARALLEL Meaning: The printer is receiving PCL5e data through the parallel interface. Action: None required. PCL TOKEN-RING Meaning: The printer is receiving PCL5e data through the token-ring interface.

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Action: None required. PJL PARALLEL Meaning: The printer is receiving or sending PJL information through the parallel interface. Action: None required. PLEASE WAIT Meaning: The printer is processing data and cannot immediately respond to a request. Action: Wait until the message clears. If the message remains and processing on the host appears to have stopped, power off the printer, wait ten seconds, and then power on the printer. POWER SAVER ON Meaning: The printer is in power-saving mode and has temporarily shut off power to certain of its components. Power will be restored as soon as a job is submitted. Action: None required. PS ETHERNET Meaning: The printer is receiving PostScript data through the Ethernet interface. Action: None required. PS PARALLEL Meaning: The printer is receiving PostScript data through the parallel interface. Action: None required. PS TOKEN-RING Meaning: The printer is receiving PostScript data through the token-ring interface. Action: None required. READY Meaning: The printer is ready to receive data. Action: None required.

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+ REALLY FORMAT / - IGNORE DISK Meaning: You have asked to format the hard drive. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to cancel the formatting. RECONFIGURING MEMORY Meaning: The printer has received a print job that requires it to adjust memory settings for the current page. Action: No action is required. The printer recongures its memory settings to print the current page. Afterward, its settings revert to normal. RESETTING PRINTER Meaning: The printer is resetting to its defaults. Action: None required. RESTORING DEFAULTS Meaning: The printer is restoring the defaults. Action: None required. SWITCHING TO IPDS Meaning: The printer is switching to IPDS. Action: None required. SWITCHING TO PCL Meaning: The printer is switching to PCL5e. Action: None required. SWITCHING TO PS Meaning: The printer is switching to PostScript. Action: None required.

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WAIT FOR IDLE PRINTER Meaning: You attempted to print from the Test Menu while the printer was processing PCL, PostScript, or IPDS data. Action: When a port timeout occurs for the data stream (PCL5e, PostScript, or IPDS), the READY message appears on the operator panel. Wait for the READY message and then try printing again. WARMING UP Meaning: The printer is warming up. When it is warm, it displays the READY message. Action: None required. If the message seems to appear too frequently, change the value for the power-saving mode to a larger value. If the message remains on the display and nothing prints, wait three minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to Operator Panel, Controller, and Power Problems on page 135.

Chapter 2. Diagnosing Problems 246

Chapter 3. Diagnostic Tools


Operator Control Panel . . . . . . . . . . . . . . . . Conguration Page . . . . . . . . . . . . . . . . . . Test Prints . . . . . . . . . . . . . . . . . . . . . . . Running Paper Path Test Prints . . . . . . . . . . . Printing a Test Matrix Page from the DIAGNOSTICS Printing a Test Matrix Page Without the Controller . Cold Reset. . . . . . . . . . . . . . . . . . . . . . . MACHINE INFO MENU . . . . . . . . . . . . . . . . Error Log. . . . . . . . . . . . . . . . . . . . . . . Counters . . . . . . . . . . . . . . . . . . . . . . . Service Mode . . . . . . . . . . . . . . . . . . . . . DIAGNOSTICS MENU. . . . . . . . . . . . . . . . D01 TEST PRINT . . . . . . . . . . . . . . . . . Output Tests . . . . . . . . . . . . . . . . . . . . D11 CHECK SUM . . . . . . . . . . . . . . . . . D13 FUSER TEMP (Current Setting) . . . . . . . D21 SENSOR TEST . . . . . . . . . . . . . . . . D23 TEST FAN . . . . . . . . . . . . . . . . . . D41 CLUTCH TR (Turn Roll Clutch) . . . . . . . . D43 CLUTCH REG (Registration Clutch) . . . . . D44 HCF UP (Tray Lifts). . . . . . . . . . . . . . D45 HCF DOWN (Tray Lowers) . . . . . . . . . . D50 SOL TRAY A (Auxiliary Tray Feed Solenoid) . D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid) . D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid) . D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid) . D60 DRIVE MOTOR MAIN . . . . . . . . . . . .
Copyright IBM Corp. 1998

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.249 .250 .251 .251 .251 .252 .253 .254 .254 .255 .256 .257 .257 .257 .258 .259 .261 .267 .269 .271 .273 .275 .277 .279 .281 .283 .285 247

D63 MOTOR D CW (Duplex Motor Runs CW) . . . . D64 MOTOR D CCW (Duplex Motor Runs CCW) . . . D68 HCF MOTOR (HCF Transport Motor). . . . . . . FACTORY ADJ MENU . . . . . . . . . . . . . . . . . . A01 Reg Top 1 (Leading Edge Registration, Tray 1) . A03 Reg Top 2 (Leading Edge Registration, Tray 2) . A05 Reg Top 3 (Leading Edge Registration, Tray 3) . A07 Reg Top A (Leading Edge Registration, Aux. Tray) A09 Reg Left 1 (Left Edge Registration, Tray 1). . . . A11 Reg Left 2 (Left Edge Registration, Tray 2) . . . . A13 Reg Left 3 (Left Edge Registration, Tray 3). . . . A15 Reg Left A (Left Edge Registration, Aux. Tray) . . A21 Fuser Temp (Adjustment) . . . . . . . . . . . . . S/N = 00-00000 (Serial Number) . . . . . . . . . . . Menu Items Not Described . . . . . . . . . . . . . . . .

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Operator Control Panel

v v v v v v

Press Press Press Press Press Press

Online to toggle the printer online or offline. Menu to scroll through menus. Item to scroll through menu items. Value to scroll through values for a menu item. Shift to reverse the scroll direction. Enter to accept a menu item or value selection.

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Conguration Page
1. 2. 3. 4. Press Press Press Press Online to take the printer offline. Menu. The message TEST MENU appears. Item. The message CONFIG PAGE appears in the second line. Enter to print the conguration page.

Notes: 1. The conguration pages print from the PAPER MENU/SOURCE. 2. To print continuous conguration pages, press Item until CONTINUOUS TEST appears, then press Enter. To stop, press Cancel Print and wait for up to 10 pages. 3. To print duplex continuous conguration pages, set PAPER MENU/DUPLEX=ON. 4. If the serial number printed on the conguration page does not match the printer serial number, see S/N = 00-00000 (Serial Number) on page 305. (See Figure 5 on page 363 for the location of the printer serial number.)

Chapter 3. Diagnostic Tools 250

Test Prints Running Paper Path Test Prints


1. 2. 3. 4. 5. 6. Press Online to take the printer offline. Press Menu to select PAPER MENU. Press Item to scroll to the desired input paper SOURCE. Press Enter. An asterisk (*) appears next to your choice. Press Menu to scroll to the TEST MENU. Press Item to scroll to the desired test page. v CONFIG PAGE prints the menu settings. v DEMO includes shading. v CONTINUOUS TEST prints multiple conguration pages (press Cancel Print to stop printing after 10 or so pages). 7. Press Enter to print the test page.

Printing a Test Matrix Page from the DIAGNOSTICS MENU


Go to D01 TEST PRINT on page 257.

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Printing a Test Matrix Page Without the Controller


This procedure prints a test page without a controller installed. It provides a ground spike to the test print signal (/TESTPRINT) at MCU P23, which creates the test page. The procedure can help isolate MCU or print engine problems versus controller problems (if the test page prints, the MCU and the print engine are functional). It can be used for adjusting print registration from Tray 1. 1. Power OFF the printer. 2. Remove the controller. 3. Locate P23, which is the 2-pin connector near the upper right corner of the MCU (there is no cable attached). 4. Close the printer covers. Ensure that tray 1 has paper and is installed. 5. Connect a jumper to the pins of P23. Note: If you do not have a jumper, you can use one from a Controller SIMM. Before removing a jumper, note its location for reinstallation. 6. Power ON the printer. The main motor and the fan turn on as the MCU tests the printer. 7. If the MCU and the print engine are operating correctly, a test page prints within two minutes. Note: If a test page does not print, ensure that the jumper in P23 is secure. Retry the procedure. If a test page still does not print, ensure that there are no error conditions, such as an empty paper tray, paper jam, or open covers. 8. Test pages will continue to print (simplex) until the jumper is removed. If the duplex option is installed, removing and replacing the jumper will print test pages (duplex) until the jumper is removed again. 9. If you used a jumper from a Controller SIMM, reinstall the jumper on the Controller SIMM. Note: MCU-detected errors, such as a fan problem, cause the printer to stop before printing a test page. With the controller installed, these MCU-detected errors display with error codes of 5n (See Chapter 2. Diagnosing Problems on page 37).
Chapter 3. Diagnostic Tools 252

Cold Reset
The following procedure resets all values in printer NVRAM to factory defaults, and clears the error log. 1. Print a conguration page (see Conguration Page on page 250). 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display.

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MACHINE INFO MENU Error Log


To 1. 2. 3. 4. display the last 10 error message entries: Press Online to take the printer offline. Press Menu to select the MACHINE INFO Menu. Press Item to select ERROR LOG. Press Enter to display the most recent entry.

Note: Common errors, such as COVER OPEN, are not logged. 5. Press Value to scroll through the list. 6. Press Shift and Enter at the same time to clear the error log. Note: The Error Log can also be printed by Running Paper Path Test Prints on page 251.

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Counters
The Machine Info Menu also displays information about printer supply usage. From the Machine Info Menu, select the desired counter:
Machine Info Menu Item PAGE COUNT ERROR LOG TONER COUNTER Description Displays the number of pages the printer has printed. Displays the error log. Use the Value key to scroll through the list. Displays the EP cartridge count. IBM recommends resetting this counter whenever you change toner cartridges. To reset the counter: 1. Simultaneously press the Shift and Value keys. 2. Press the Enter key. Displays the fuser counter. IBM recommends resetting this counter whenever you change the usage kit. To reset the counter: 1. Simultaneously press the Shift and Value keys. 2. Press the Enter key.

FUSER COUNTER

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Service Mode
The service mode consists of two service menus: the DIAGNOSTICS MENU and the FACTORY ADJ MENU. To display a service menu: 1. Power OFF the printer. 2. Turn on the printer power while pressing Item and Value simultaneously for a few seconds. Wait until the message DIAGNOSTICS MENU appears. 3. Press Menu to select the service menu (DIAGNOSTICS MENU or FACTORY ADJ MENU). To 1. 2. 3. select a test or item in the DIAGNOSTICS MENU or FACTORY ADJ MENU: Press Item to scroll through the tests or items. Press Enter when you reach the test or item you want to run. Press Cancel Print to temporarily stop an action test, such as a motor running test. Then press Enter to restart the same test.

Chapter 3. Diagnostic Tools 256

DIAGNOSTICS MENU
D01 TEST PRINT
Prints a test matrix page from Tray 1. Before performing this test, make sure Tray 1 has paper. There is no error reporting with this test. To run D01 TEST PRINT: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D01 TEST PRINT displays. Press Enter to begin printing from Tray 1. After the print completes, press Item to step to another item in the DIAGNOSTICS MENU

See Test Prints on page 251 for more information on running test prints.

Output Tests
The output tests fall into two groups: v Displaying the fuser temperature control setting and the current fuser temperature v Actuating components Once the unit starts executing an output test, the only diagnostic codes accessible are those for output tests. It is thus impossible to break out of the output test mode. Turning the interlock switch off is another way of terminating the display of the accumulated print count. The output tests permit the parallel operation of multiple components.

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D11 CHECK SUM


The diagnostic test displays the checksum of the printer ROM. The LCD displays the checksum as a four-digit number. To run D11 CHECK SUM: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D11 CHECK SUM displays. Press Enter to begin test. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

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D13 FUSER TEMP (Current Setting)


Diagnostic code D13 executes immediatly if any of the other output tests is being executed. To run D13 FUSER TEMP: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the test or items. 3. Stop pressing Item when D13 FUSER TEMP displays. 4. Press Enter to begin test. A screen displays the factory adjustment fuser temperature (SET) and the actual fuser temperature (ACT) in HEX. Note: If you need to change the SET value, go to A21 Fuser Temp (Adjustment) on page 304. 5. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. Note: Because the fuser is constantly moving through a range of temperatures (warming and cooling), it is normal for the fuser temperature to change as you run the test. Check the two-digit hexadecimal number that appears in the lower right corner of the LCD. It is a code that gives the two running temperatures for controlling the fuser temperature: the normal temperature and the high temperature.

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The following chart lists the temperature code settings and the corresponding temperature ranges.
Table 57. Fuser Temperature Codes
Code Temperature Code Range [Normal Temp./High Temp.] (Hexadecimal) Fuser Temperature [Normal Temp./High Temp.] (C) Approximate 0 1 2 3 4 5 6 7 8 9 A B C D E F C2 / B2 BF / AF BC / AC B9 / A9 B6 / A6 B3 / A3 B0 / A0 AD / 9D AA / 9A A7 / 97 A4 / 94 A1 / 91 9E / 8E 9B / 8B 98 / 88 95 / 85 155 / 172 158 / 175 162 / 178 165 / 181 168 / 184 171 / 187 174 / 190 177 / 193 180 / 196 183 / 199 186 / 202 189 / 205 192 / 208 195 / 211 198 / 215 201 / 218

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D21 SENSOR TEST


This diagnostic test checks the function of sensors and switches within the printer. Note: The toner sensor input test does not work if the interlock switch is off.

To run D21 SENSOR TEST: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Press Item to step through the tests or items. Stop pressing Item when D21 SENSOR TEST displays. Press Enter to begin test. Manually activate and deactivate the sensor or the switch you want to test. If a sensor or switch is functioning correctly, SENSOR OK displays. If the sensor is not functioning correctly, Activate Sensor continues to display. 6. To exit this test activate a sensor that functions correctly, then press Item to step to another item in the DIAGNOSTICS MENU. Note: See Figure 3 on page 265 and Figure 4 on page 266 for the locations of the following items.

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Items Tested and Relevant Procedures:


Item Interlock switch Fuser cover switch CRU switch in CRU sensor assembly (See Caution <233>). Feeder PWB paper size switches for trays 1-3 AUX tray no paper sensor Tray 1, 2, or 3 no paper sensor Registration sensor Procedure With the EP cartridge removed, open and close the pop up unit to turn the interlock switch off and on. Open and close the fuser cover to turn the fuser cover switch off and on. First disconnect either the P/J12 connector on the MCU PWB or the P/J112 connector in the ROS assembly. With the pop up unit open, use a small screwdriver or other implement to turn the CRU sensor assembly actuator on and off. Use your hand or other means to move the size actuators and thus turn the feeder PWB paper size switches on and off. Use your hand or other means to move the AUX tray no paper actuator to switch the AUX tray no paper sensor between its no paper and paper positions. Use your hand or other means to move the tray 1, 2, or 3 no paper actuator to switch the tray 1, 2, or 3 no paper sensor between its no paper and paper positions. Use a sheet of paper or other means to move the registration actuator to switch the registration sensor between its no paper and paper positions. You may need a ashlight to see the actuator in the small rectangular recess at the center of the area behind the toner cartridge. Open the fuser cover and the fuser jam access cover. Use a sheet of paper or other means to move the exit actuator to switch the exit sensor between its no paper and paper positions. The sensor is part of the fuser. Use your hand or other means to move the full stack actuator to switch the full stack sensor between its no paper and paper positions. The sensor is ignored if the Duplex option is installed.

Exit sensor

Full stack sensor

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Item Toner sensor

Procedure Disconnect P/J171 at the CRU sensor assembly or P/J17 at the MCU; this ensures that the laser will not turn on if you accidentally activate the CRU sensor. If the duplex option is installed, you can open the duplex cover to disable the laser. With the interlock switch on, install and remove an EP cartridge containing toner, or activate with a non-magnetic metal tool. With the duplex unit lower cover closed, open and close the duplex unit upper cover to turn the duplex cover switch 1 on and off. With the duplex unit upper cover closed, open and close the duplex unit lower cover to turn the duplex cover switch 2 on and off. Open the duplex unit upper cover. Use your hand or other means to move the duplex pass sensor actuator and thus turn the duplex pass sensor on and off. Use your hand or other means to move the DUP stack actuator to switch the DUP stack sensor between its no paper and paper positions. Open the HCF rear cover. Override the left and right cover open switches. Cover and uncover the sensor. Cannot be tested with D21. Remove the left hand side plate. Depress the switch. Remove the front cover. Depress the switch. Open the HCF rear cover on the left side only. Opening the cover will change the state of the switch. Open the HCF rear cover on the right side only. Opening the cover will change the state of the switch. With the HCF drawer pulled out and the elevator in the down position, depress both the tray set sensor 1 and tray set sensor 2. Activate D21 and release tray set sensor 1. (Do not allow the bottom plate to rise near the top of the drawer. Damage will occur by not coming in contact with the upper limit switch).

Duplex cover switch 1 Duplex cover switch 2 Duplex pass sensor DUP stack sensor HCF Exit sensor HCF Lower position sensor HCF size sensor HCF Near empty sensor HCF left hand cover open switch HCF right hand cover open switch HCF tray set sensor 1

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Item HCF tray set sensor 2 Upper limit switch

Procedure Cannot test with D21 With the elevator in the down position, open the front door and activate D21. Reach inside and push up on the feed roller bracket until you hear a click. This will activate the upper limit switch. Push the actuator up into the paper level sensor. Push up on the paper out sensor. The paper out actuator and sensor are part of the feed roller bracket assembly.

HCF paper level sensor HCF paper out sensor

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Full Stack Actuator Full Stack Sensor Exit Chute Roll

Pinch Roll

Exit Roll Assembly Exit Sensor CRU Switch Control Assembly (Console Assembly) Exit Sensor Full Stack Sensor Exit Actuator Fuser Assembly

Toner Sensor

Registration Sensor

Rubber Registration Roll Metal Registration Roll

Registration Sensor

MSI (Aux) No Paper Sensor


hc2m979F

Pick Up Roll

Registration Actuator

Figure 3. Sensor and Switch Locations I

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Fuser Cover

Interlock Actuator

Pop Up Cover Assembly

Fuser Cover Switch

FRONT
Fuser Cover Switch Interlock Switch

Interlock Switch Size Cam

Size Actuator

Paper Size Switch

Paper Size Switch

Feeder PWB

CST No Paper Sensor

Feed Roll
hc2m980F

CST No Paper Actuator CST No Paper Sensor

Figure 4. Sensor and Switch Locations II

Chapter 3. Diagnostic Tools 266

D23 TEST FAN


This diagnostic test runs the fan at high speed.

Fan

MCU

FRONT

hc2m993F

Chapter 3. Diagnostic Tools 267

To run D23 TEST FAN: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D23 TEST FAN displays. Press Enter to begin test. Verify that when you press Enter, the fan is running at high speed. Verify that the fan is running at high speed from the noise that it makes or from the wind pressure. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. Note: The fan runs at low speed whenever the power is on. It switches to high speed when the main motor is on. This test switches the fan from low speed to high speed.

Chapter 3. Diagnostic Tools 268

D41 CLUTCH TR (Turn Roll Clutch)


This diagnostic code tests all the Electromagnetic Turn Roll Clutches (tray 1, 2, and 3).

FRONT

MCU PWB

Electromagnetic Turn Roll Clutch (Tray 1) Electromagnetic Turn Roll Clutch (Tray 2) Electromagnetic Turn Roll Clutch (Tray 3)

hc2m985F

Chapter 3. Diagnostic Tools 269

To run D41 CLUTCH TR: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D41 CLUTCH TR displays. Press Enter to begin test. Verify that when you press Enter, the turn roll clutch actuates. Conrm clutch operation by listening for the slight click of operation or manually rotating the corresponding driven rollers (rubber registration roll and turn roll assembly) to conrm that they are no longer free, but xed to the drive system. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Chapter 3. Diagnostic Tools 270

D43 CLUTCH REG (Registration Clutch)


This diagnostic code tests the Registration Clutch Assembly.

Metal Registration Roll

FRONT

hc2m986F

MCU PWB Registration Clutch Assembly

Chapter 3. Diagnostic Tools 271

To run D43 CLUTCH REG: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D43 CLUTCH REG displays. Press Enter to begin test. Verify that when you press Enter, the registration clutch actuates. Conrm clutch operation by listening for the slight click of operation or manually rotating the corresponding driven rollers (rubber registration roll and turn roll assembly) to conrm that they are no longer free, but xed to the drive system. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Chapter 3. Diagnostic Tools 272

D44 HCF UP (Tray Lifts)


This tests the lifting of the bottom plate.

hc2m026F

Chapter 3. Diagnostic Tools 273

To run D44 HCF UP, perform the following: 1. Enter the DIAGNOSTICS MENU (see Service Mode on page 256). 2. Repeatedly press Item, stepping through the menu until D44 HCF UP displays. 3. Press Enter; you should hear the elevator motor run. 4. To view the travel of the bottom plate, open the HCF rear cover and manually close the left and right hand cover open switches. Press Cancel Print to stop the test; press Enter to restart the test.

Chapter 3. Diagnostic Tools 274

D45 HCF DOWN (Tray Lowers)


This tests the lowering of the bottom plate.

hc2m026F

Chapter 3. Diagnostic Tools 275

To run D45 HCF DOWN, perform the following: 1. Enter the DIAGNOSTICS MENU (see Service Mode on page 256). 2. Repeatedly press Item, stepping through the menu until D45 HCF DOWN displays. 3. Press Enter; you should hear the elevator motor run. 4. To view the travel of the bottom plate, open the HCF rear cover and manually close the left and right hand cover open switches. Press Cancel Print to stop the test; press Enter to restart the test.

Chapter 3. Diagnostic Tools 276

D50 SOL TRAY A (Auxiliary Tray Feed Solenoid)


This diagnostic code tests the Auxiliary Tray paper pick solenoid. The solenoid picks for approximately 0.5 seconds. After that interval, the solenoid automatically turns off.

MCU PWB

Pick Up Solenoid

hc2m983F

Chapter 3. Diagnostic Tools 277

To run D50 SOL TRAY A: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D50 SOL TRAY A displays. Press Enter to begin test. Verify that when you press Enter, the AUX feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. The solenoid may now be in a pre-pick condition. Remove paper from the Auxiliary Tray and switch the printer off, and then on to reset the solenoid (if you do not remove paper you may get a 24 PAPER JAM when the motor is tested during power up).

Chapter 3. Diagnostic Tools 278

D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid)


This diagnostic test actuates the Tray1 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. After that interval, the solenoid automatically turns off.

FRONT

D51
MCU PWB

D52
Feed Solenoid

D53
Feed Solenoid

hc2m984F

Feed Solenoid

Chapter 3. Diagnostic Tools 279

To run D51 SOLENOID TRAY1: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D51 SOLENOID TRAY1 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 1 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Chapter 3. Diagnostic Tools 280

D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid)


This diagnostic test actuates the Tray2 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. After that interval, the solenoid automatically turns off.

FRONT

D51
MCU PWB

D52
Feed Solenoid

D53
Feed Solenoid

hc2m984F

Feed Solenoid

Chapter 3. Diagnostic Tools 281

To run D52 SOLENOID TRAY2: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D52 SOLENOID TRAY2 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 2 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Chapter 3. Diagnostic Tools 282

D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid)


This diagnostic test actuates the Tray3 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. After that interval, the solenoid automatically turns off.

FRONT

D51
MCU PWB

D52
Feed Solenoid

D53
Feed Solenoid

hc2m984F

Feed Solenoid

Chapter 3. Diagnostic Tools 283

To run D53 SOLENOID TRAY3: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D53 SOLENOID TRAY3 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 3 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Chapter 3. Diagnostic Tools 284

D60 DRIVE MOTOR MAIN


The diagnostic code switches on the Main Motor.

FRONT

hc2m987F

MCU PWB Main Motor

Chapter 3. Diagnostic Tools 285

To run D60 DRIVE MOTOR MAIN: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D60 DRIVE MOTOR MAIN displays. Press Enter to begin test. Verify that when you press Enter, the main motor switches on and rotates. Conrm motor operation by listening for the sound of operation or by visual observation. 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. 2. 3. 4. 5.

Chapter 3. Diagnostic Tools 286

D63 MOTOR D CW (Duplex Motor Runs CW)


The diagnostic test switches on the Duplex Motor with clockwise rotation.

Duplex Motor

Duplex Upper Roll Pinch Roll


Duplex Sensor

Duplex Lower Roll Rear Roll Assembly

hc2m823F

Chapter 3. Diagnostic Tools 287

To run D63 MOTOR D CW: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D63 MOTOR D CW displays. Press Enter to begin test. Verify that when you press Enter, the duplex motor switches on and rotates. Conrm motor operation by listening for the sound of operation or by visual observation. 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. 2. 3. 4. 5.

Chapter 3. Diagnostic Tools 288

D64 MOTOR D CCW (Duplex Motor Runs CCW)


The diagnostic test switches on the Duplex Motor in counter-clockwise rotation.

Duplex Motor

Duplex Upper Roll Pinch Roll


Duplex Sensor

Duplex Lower Roll Rear Roll Assembly

hc2m823F

Chapter 3. Diagnostic Tools 289

To run D64 MOTOR D CCW: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D64 MOTOR D CCW displays. Press Enter to begin test. Verify that when you press Enter, the duplex motor switches on and rotates in a counter-clockwise direction (Open the cover and override the interlock to watch the motor rotate). 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. Conrm motor operation by listening for the sound of operation or by visual observation. 2. 3. 4. 5.

Chapter 3. Diagnostic Tools 290

D68 HCF MOTOR (HCF Transport Motor)

1
hc2m042F

Chapter 3. Diagnostic Tools 291

To run D68 HCF MOTOR: 1. Enter the DIAGNOSTICS MENU (see Service Mode on page 256). 2. Repeatedly press Item, stepping through the menu until D68 HCF MOTOR displays. 3. Press Enter; you should hear the HCF transport motor run. 4. To view the transport roll turning, open the HCF rear cover and manually close the left and right hand cover open switches. Press Cancel Print to stop the test; press Enter to restart the test.

Chapter 3. Diagnostic Tools 292

FACTORY ADJ MENU


Table 58. Factory Adjustment Menu Items
Code A01 Message Reg Top 1 Function Sets the top (lead) edge registration for paper fed from tray 1. 0-15 (16 steps) (Factory default 10) 0=Narrowest top edge registration gap 15=Widest top edge registration gap (approximately 0.5 mm per step) (Go to A01 Reg Top 1 (Leading Edge Registration, Tray 1) on page 296.) A03 Reg Top 2 Sets the top (lead) edge registration for paper fed from tray 2. 0-15 (16 steps) (Factory default 10) 0=Narrowest top edge registration gap 15=Widest top edge registration gap (approximately 0.5 mm per step) (Go to A03 Reg Top 2 (Leading Edge Registration, Tray 2) on page 297.) A05 Reg Top 3 Sets the top (lead) edge registration for paper fed from tray 3. 0-15 (16 steps) (Factory default 10) 0=Narrowest top edge registration gap 15=Widest top edge registration gap (approximately 0.5 mm per step) (Go to A05 Reg Top 3 (Leading Edge Registration, Tray 3) on page 298.)

Chapter 3. Diagnostic Tools 293

Table 58. Factory Adjustment Menu Items (continued)


Code A07 Message Reg Top A Function Sets the top (lead) edge registration for paper fed from auxiliary tray. 0-15 (16 steps) (Factory default 10) 0=Narrowest top edge registration gap 15=Widest top edge registration gap (approximately 0.54 mm per step) (Go to A07 Reg Top A (Leading Edge Registration, Aux. Tray) on page 299.) A09 Reg Left 1 Sets the left edge registration for paper fed from tray 1. 0-8 (9 steps) (Factory default 4) 0=Narrowest left edge registration gap 8=Widest left edge registration gap (approximately 0.5 mm per step) (Go to A09 Reg Left 1 (Left Edge Registration, Tray 1) on page 300.) A11 Reg Left 2 Sets the left edge registration for paper fed from tray 2. 0-8 (9 steps) (Factory default 4) 0=Narrowest left edge registration gap 8=Widest left edge registration gap (approximately 0.5 mm per step) (Go to A11 Reg Left 2 (Left Edge Registration, Tray 2) on page 301.)

Chapter 3. Diagnostic Tools 294

Table 58. Factory Adjustment Menu Items (continued)


Code A13 Message Reg Left 3 Function Sets the left edge registration for paper fed from tray 3. 0-8 (9 steps) (Factory default 4) 0=Narrowest left edge registration gap 8=Widest left edge registration gap (approximately 0.5 mm per step) (Go to A13 Reg Left 3 (Left Edge Registration, Tray 3) on page 302.) A15 Reg Left A Sets the left edge registration for paper fed from auxiliary tray. 0-8 (9 steps) (Factory default 4) 0=Narrowest left edge registration gap 8=Widest left edge registration gap (approximately 0.5 mm per step) (Go to A15 Reg Left A (Left Edge Registration, Aux. Tray) on page 303.) A21 Fuser Temp Sets the rated fuser temperature. Note: This setting is intended for manufacturing and engineering use. Keep at factory default. 0-15 (16 steps) (Factory default 5) 0=Lowest rated temperature. 15=Highest rated temperature. (approximately 4.0C per step) (Go to A21 Fuser Temp (Adjustment) on page 304.)

Chapter 3. Diagnostic Tools 295

A01 Reg Top 1 (Leading Edge Registration, Tray 1)


This factory adjustment sets the top (lead) edge registration for paper fed from Tray 1. Use A01 REG TOP 1 to verify that there is a registration problem in Tray 1. (See page 257.) To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A01 REG TOP 1 displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 296

A03 Reg Top 2 (Leading Edge Registration, Tray 2)


This factory adjustment sets the top (lead) edge registration for paper fed from Tray 2. Use a real job printed from Tray 2 to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A03 REG TOP 2 displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 297

A05 Reg Top 3 (Leading Edge Registration, Tray 3)


This factory adjustment sets the top (lead) edge registration for paper fed from Tray 3. Use a real job printed from Tray 3 to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A05 REG TOP 3 displays. 4. PressValue to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 298

A07 Reg Top A (Leading Edge Registration, Aux. Tray)


This factory adjustment sets the top (lead) edge registration for paper fed from the AUX tray. Use a real job printed from the AUX tray to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A07 REG TOP A displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 299

A09 Reg Left 1 (Left Edge Registration, Tray 1)


This factory adjustment sets the left edge registration for paper fed from Tray 1. Use D01 TEST PRINT to verify that there is a registration problem. (See page 257.) To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A09 REG LEFT 1 displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 300

A11 Reg Left 2 (Left Edge Registration, Tray 2)


This factory adjustment sets the left edge registration for paper fed from Tray 2. Use a real job printed from Tray 2 to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A11 REG LEFT 2 displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 301

A13 Reg Left 3 (Left Edge Registration, Tray 3)


This factory adjustment sets the left edge registration for paper fed from Tray 3. Use a real job printed from Tray 3 to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A13 REG LEFT 3 displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 302

A15 Reg Left A (Left Edge Registration, Aux. Tray)


This factory adjustment sets the left edge registration for paper fed from the auxiliary tray. Use a real job printed from the AUX tray to verify that there is a registration problem. To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A15 REG LEFT A displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 303

A21 Fuser Temp (Adjustment)


This factory adjustment sets the fuser temperature. Use D13 FUSER TEMP (Current Setting) to show the current setting and actual reading. (See page 259.) To perform the adjustment: 1. Enter the FACTORY ADJ MENU (See Service Mode on page 256). 2. Repeatedly press Item to step through the adjustments or items. 3. Stop pressing Item when A21 FUSER TEMP displays. 4. Press Value to increase a factory adjustment value (CODE). Press Shift+Value to decrease a factory adjustment value (See Table 57 on page 260 and Table 58 on page 293). 5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asterisk following the value indicates the value is stored in engine NVRAM. 6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.

Chapter 3. Diagnostic Tools 304

S/N = 00-00000 (Serial Number)


The following procedure enters the printer serial number into the printer MCU NVRAM (see Figure 5 on page 363 for the location of the printer serial number). This allows the correct serial number to print on the conguration page. This value is set at the factory. Use this procedure only if you have installed a new MCU PWB. To run S/N = 00-00000, perform the following: 1. Enter the FACTORY ADJ MENU (see FACTORY ADJ MENU on page 293). 2. Repeatedly press Shift+Item to wrap to the end of the menu item list, S/N = 00-00000 will be displayed. You are now ready to change the left most position of the serial number. 3. Press Value to increase the number, or press Shift Value to decrease the number in that position. Each position has a numerical range from 09, and an alpha range from AF. 4. Press Enter to accept the value and move to the next position. 5. Repeat for each position. After the last position is enterd, press Enter again until an asterisk appears at the right of the serial number. This indicates that the updated serial number information has been stored in the printer NVRAM. 6. Switch printer power off, and then on again.

Chapter 3. Diagnostic Tools 305

Menu Items Not Described


The following menu items are not described. If necessary, technical support will guide you through them. v D81 HVPS CHG DC v D83 HVPS DEV BIAS DC v A22 PRF=Enable/Disable v A22 SFS=Enable/Disable v A23 TNS=Enable/Disable v A26 OCT=Enable/Disable v A27 FUS=Enable/Disable

Chapter 3. Diagnostic Tools 306

Chapter 4. Circuit Diagrams


Master Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310 Wiring and Signal Description between Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 MCU LVPS INTERLOCK SWITCH and FANs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311 Signal names for the MCU LVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312 MCU FUSER ASSEMBLY LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313 Signal names for the MCU Fuser Assembly path . . . . . . . . . . . . . . . . . . . . . . . . . . .314 Pin numbers and voltage levels for the MCU Fuser Assembly path . . . . . . . . . . . . . . . . . .314 MCU ROS and CRU SENSOR ASSEMBLY (CRU SWITCH and LD SWITCH) . . . . . . . . . . . . .315 Signal names for the MCU ROS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316 Pin numbers and voltage levels for the MCU ROS path . . . . . . . . . . . . . . . . . . . . . . . .317 Selection of the print resolution with SP11 and SP12 . . . . . . . . . . . . . . . . . . . . . . . . . . .318 MCU HVPS EP CARTRIDGE (BCR and MAG. ROLL), BTR, and DETACK SAW . . . . . . . . . .319 Signal names for the MCU HVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320 Pin numbers and voltage levels for the MCU HVPS path . . . . . . . . . . . . . . . . . . . . . . .321 MCU REG. CLUTCH, REG. SENSOR, PICK UP SOLENOID, and AUX TRAY NO-PAPER SENSOR . .322 Signal names for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323 Pin numbers and voltage levels for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324 MCU FEEDER1 PWB FEED SOLENOID, CST NO-PAPER SENSOR, and ELECTROMAGNETIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325 Signal names for the MCU FEEDER1 PWB path . . . . . . . . . . . . . . . . . . . . . . . . . . .326 Pin numbers and voltage levels for the MCU FEEDER1 PWB path . . . . . . . . . . . . . . . . . .328 MCU MAIN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329 Signal names for the MCU Main Motor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330 Pin numbers and voltage levels for the MCU Main Motor path. . . . . . . . . . . . . . . . . . . . .330 MCU TONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331
Copyright IBM Corp. 1998

307

Signal names for the MCU Toner Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the MCU Toner Sensor path. . . . . . . . . . . . . . . . . . MCU DUPLEX I/F PWB FUSER COVER SWITCH or MCU FUSER COVER SWITCH . . . . Signal names for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path . . . . . . . . . Pin numbers and voltage level for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path Signal names for the MCU FUSER COVER SWITCH path . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage level for the MCU FUSER COVER SWITCH path. . . . . . . . . . . . CONTROLLER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Controller Control Panel path . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the CONTROLLER CONTROL PANEL path . . . . . . . . . CONTROLLER MCU and LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Controller MCU path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Controller MCU path . . . . . . . . . . . . . . . . . . . Signals between the Controller and the MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MCU Feeder PWB Feeder PWB Feeder PWB Feed Solenoid, No Paper Sensor, and Electromagnetic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Feeder PWB Feeder PWB path . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Feeder PWB (Feeder1) Feeder PWB (Feeder2) path . . . Pin numbers and voltage levels for the Feeder PWB (Feeder2) Feeder PWB (Feeder3) path . . . Detection of the Feeder conguration through the FEEDER CHECK signal. . . . . . . . . . . . . . MCU Duplex I/F PWB Duplex PWB and Fuser Cover Switch Duplex PWB Dup Stack Sensor, Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor . . . Signal names for the Duplex I/F PWB Duplex PWB path . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Duplex I/F PWB Duplex PWB path . . . . . . . . . . . . Signal names for the Duplex PWB Offset Motor path . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Duplex PWB Offset Motor path . . . . . . . . . . . . . . HCF LVPS Components, HCF LVPS FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . Signal names for the HCF LVPS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the HCF LVPS FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . .

.331 .331 .332 .333 .333 .333 .333 .334 .335 .336 .337 .338 .338 .339 .342 .344 .345 .346 .347 .349 .350 .351 .351 .352 .353 .354 .356

Chapter 4. Circuit Diagrams 308

Pin numbers and voltage levels for the HCF LVPS Components. . . . . . . . . . . . . . . . . . . .357

Chapter 4. Circuit Diagrams 309

Master Wiring Diagram


ROS LD EP Cartridge
P/J 112

OPTIONAL
P/J 114
TURN CLH

P/J 113

P/J206 P/J205

SOS

MOT

DB CR DTS TR

P/J12 P/J 15 P/J 16

NO PAPER

P/J 203

FEEDER3

P/J204

HVPS

P/J 151

FEED SOL

P/J904

MAIN MOT

M
P/J 171
P/J221 P/J922 P/J222

MCU

P201 P207

OPTIONAL
OCT MOT

FULL COVER COVER DUP SWITCH1 SWITCH2 MOT SNS

/DUP

/DUP

DUP SNS

CRU SNS

P/J 17
TURN CLH

P202
P/J206 P/J205

M
P/J 196 P/J 192 P/J 193 P/J 198

M
P/J 197 P/J 195

TONER SNS

P/J 22

NO PAPER

P/J 203

FEEDER2

P/J204

P/J 186

P/J184
DUPLEX PWB

P/J187

REG CLH REG SNS NOP SNS AUX AUX P182 P/J 132

P/J131

FEED SOL

P/J904

P201 P/J 13 P/J 20 P207 P202 P/J 19


CONTROLLER CONTROL PANEL
TURN CLH

P183

P/J937

P/J 134 FEED SOL

P/J137

P/J135

P/J935

P/J206 P/J205

NO PAPER

P/J 203

FEEDER1

P/J204

COVER SWITCH 190 180

P/J P/J

DUPLEX INTERFACE PWB

P/J 18 P/J 31 J131 CN1

FEED SOL

P/J904

P201

P/J143

P/J943

EXIT SENSOR

P/J 145

P/J 942

P/J 14 P23 TEST PRINT P/J21

J130

FULL STACK SENSOR

P/J 144

TEMPERATURE SENSOR

HEATER ROD
THERMOSTAT THERMAL FUSE

P/J 142 MAIN FAN P/J 122 P/J 124 P/J127

P/J11

INTERLOCK SWITCH

P/J121 P/J 123


LVPS

FUSER

COVER SWITCH

AC INLET MAIN SWITCH

P/J 126

HC2M994F

Chapter 4. Circuit Diagrams 310

Wiring and Signal Description between Components MCU LVPS INTERLOCK SWITCH and FANs
INTERLOCK SW
P/J21
2 1

24VDC 24VDC

P/J123

LVPS
P/J11
1 2 3 4 5 6 RTN 5VDC SG /HEAT(TTL) FAN ALARM(TTL) /FAN FAST ON(L)24VDC

P/J121
6 5 4 3 2 1

5VDC SUPPLY 24VDC SUPPLY

FG

FAN CONTROL HEATER CONTROL

1 2 3

1 2 3

P/J122
FAN ALARM(TTL)

MCU
FAN ON

P124
RTN

AC
hc2m995F

FG

MAIN FAN

Chapter 4. Circuit Diagrams 311

Signal names for the MCU LVPS path


Signal Name /HEAT (TTL) Description Fuser control signal to switch AC power to the Heater Rod on and off. Low: On, High: Off FAN ALARM (TTL) /FAN FAST ON(L) 24V Fan monitor signal. Goes High when the rotation of the Main Fan is abnormal. Fan speed switching signal that switches the speed of rotation of the Main Fan between High and Low. Low: High speed, High: Low speed

Chapter 4. Circuit Diagrams 312

MCU FUSER ASSEMBLY LVPS


FUSER

MCU

FULL STACK SENSOR


P/J145 P/J942 A4 A3 P/J143 2 1 P/J943 1 2 A2 A1 B1 B2 B3 B4 P/J142 A1 A2 A3 A4 B1 B2 B3 B4

1 2 3

/FULL(TTL) SG P.UP TEMP. SG /EXIT(TTL) SG P.UP

P/J14 8 7 6 5 4 3 2 1

5VDC

EXIT SENSOR
P/J144

1 2 3 TEMPERATURE SENSOR

HEAT ROLL

AC L HEATER ROD AC N
THERMOSTAT THERMAL FUSE

4 3 2 1

AC L AC N

LVPS

PRESSURE ROLL ELIMINATOR

FUSER COVER OPEN SWITCH P146-1 J146-1 P/J124


1 2 3

HEATER CONTROL

L N
FG

AC
hc2m996F

FG

FG

Chapter 4. Circuit Diagrams 313

Signal names for the MCU Fuser Assembly path


Signal Name /EXIT (TTL) TEMP. /FULL (TTL) Description Signal from the Exit Sensor. This signal is Low when the Exit Sensor is activated. Temperature monitor signal (analog signal) from the Temperature Sensor Assembly (Thermistor) that indicates the temperature of the Heat Roll surface. Signal from the Full Stack Sensor. This signal is Low when the Full Stack Sensor is activated by the stack of printed sheets higher than the predetermined height.

Pin numbers and voltage levels for the MCU Fuser Assembly path
P14 3 5 8 P142 B2 A4 A1 P942 B2 A1 A4 P144-1 P943-1 P145-1 P143-2 Signal Name /EXIT (TTL) TEMP. /FULL (TTL) Signal Direction MCUFuser MCUFuser MCUFuser Trigger Level * Level High Level TTL * TTL Low Level TTL * TTL Analog Note

Chapter 4. Circuit Diagrams 314

MCU ROS and CRU SENSOR ASSEMBLY (CRU SWITCH and LD SWITCH)
ROS
P/J114
1 2 3 4 5 6 24VDC RTN /RMOT ON(TTL) /SP11(TTL) /SP12(TTL)

P/J12
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

5VDC

MCU

MOT

P/J113
1

5VDC /SOS(TTL) SG

SOS

2 3

P/J112
1 2 3

5VDC-LD SG VL1 VL2 MO 5VDC /P.DATA(TTL)

LD

4 5 6 7

P/J17

5VDC-LD

NO CRU
1

5VDC

SG

P/J171

LD CRU SWITCH SWITCH


hc2m997F

CRU SENSOR

Chapter 4. Circuit Diagrams 315

Signal names for the MCU ROS path


Signal Name /RMOT ON (TTL) Description Scanner Motor Control signal that switches the Scanner Motor on and off. Low: On, High: Off /SP11 (TTL) /SP12 (TTL) /SOS (TTL) 5VDC-LD VL1 VL2 MO /P. DATA (TTL) Print resolution selection signal that selects a ratio of frequency division of the clock signal. Print resolution selection signal that selects a ratio of frequency division of the clock signal. Synchronization signal generated by the SOS PWBA that indicates the start of each scan. Laser Diode drive power causing the Laser Diode to emit laser light. This 5VDC supply to the Laser Diode is interrupted by the deactivation of the LD Switch in the CRU Sensor assembly. Laser power control signal that determines (or adjusts) the current owing through the Laser Diode (analog signal). Laser power control signal that dete.rmines (or adjusts) the current owing through the Laser Diode (analog signal). Laser power monitor signal that feeds back the power of the laser light emitted by the Laser Diode (analog signal). Print image data (Low = Black dot, High = White dot).

Chapter 4. Circuit Diagrams 316

Pin numbers and voltage levels for the MCU ROS path
Signal Direction M: MCU, L: LD S: SOS P112, P113, and P114 Signal Name P114-3 P114-5 P114-6 P113-2 P112-1 P112-3 P112-4 P112-5 P112-7 /RMOT ON (TTL) /SP11 (TTL) /SP12 (TTL) /SOS (TTL) 5VDC-LD VL1 VL2 MO /P. DATA (TTL) SM: Scanner Motor R: ROS PWB MCUScanner Motor MCUROS PWB MCUROS PWB MCUSOS MCUL MCUL MCUL MCUL MCUL Trigger Level Level Level Level Level High Level TTL TTL TTL TTL 5VDC * * * TTL Low Level TTL TTL TTL TTL 0V * * * TTL 0 3.5 V 0 3.5 V 0.7 1.4 V

P11 13 12 11 9 7 5 4 3 1

Note

Chapter 4. Circuit Diagrams 317

Selection of the print resolution with SP11 and SP12


Resolution SP12 600/300 dpi ROS Assembly 600 dpi * 300 dpi H H 600/360 dpi ROS Assembly 600 dpi * 360 dpi L H 600/400 dpi ROS Assembly 600 dpi * 400 dpi L L 600/480 dpi ROS Assembly 600 dpi * 480 dpi L H 480/400 dpi ROS Assembly 480 dpi * 400 dpi H L 800/600 dpi ROS Assembly 800 dpi * 600 dpi * Factory setting L L L H H L H L H L L L H L SP11

Chapter 4. Circuit Diagrams 318

MCU HVPS EP CARTRIDGE (BCR and MAG. ROLL), BTR, and DETACK SAW
CRU GUIDE ASSEMBLY L EP CARTRIDGE

DB

CRU GUIDE ASSEMBLY R

MAG. ROLL BCR

CR

HVPS

DRUM

DETACK SAW
DTS

BTR

TR

TRANS.CHUTE ASSEMBLY L

1 3 1 2 11 1 0 9 8 7 6 5 4 3 2 1

P/J151

/CR-DC ON(L) 24VDC

/DB-DC ON(L) 24VDC

/CR-AC ON(L) 24VDC

/TR(+) ON(L) 24VDC

/DTS ON(L) 24VDC

/TR ON(L) 24VDC

DTS-D/A

BTR-D/A

TRMO-V

TRMO-I

24VDC

DB-AC

RTN

1 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3

P/J15

MCU

hc2m998F

Chapter 4. Circuit Diagrams 319

Signal names for the MCU HVPS path


Signal Name DB-AC (TTL) /DB-DC ON(L) 24VDC /CR-DC ON(L) 24VDC /CR-AC ON(L) 24VDC /DTS ON(L) 24VDC /TR(+) ON(L) 24VDC Description Constant-frequency pulse signal that provides the source of oscillation for generating the AC component of the DB (Development Bias) in the HVPS. Control signal to switch the DC component of the DB on and off. Control signal to switch the DC component of the CR on and off. Control signal to switch the AC component of the CR on and off. Control signal to switch the DTS on and off. Control signal to switch the TR voltage between TR(+) and TR(-) Low: TR(+), High: TR(-). TR ON(L) 24VDC Control signal to switch the TR voltage on and off. TR(+) or TR(-) is output according to the selection by the /TR(+) ON(L) signal. TRMO-I TRMO-V BTR-D/A DTS-D/A Monitor signal of the TR(+) voltage when a constant-current output is selected by the ATDVC* (0 5 VDC). Monitor signal of the TR(+) current when a constant-voltage output is selected by the ATDVC* (0.4 4.7 VDC). Control signal to select the TR(+) voltage as determined by the ATDVC. Control signal to select the DTS voltage as determined by the ATDVC.

* Active Transfer and Detack Voltage Control

Chapter 4. Circuit Diagrams 320

Pin numbers and voltage levels for the MCU HVPS path
P15 3 4 5 6 7 8 9 10 11 12 13 P151 11 10 9 8 7 6 5 4 3 2 1 Signal Name DB-AC /DB-DC ON(L) 24VDC /CR-DC ON(L) 24VDC /CR-AC ON(L) 24VDC /DTS ON(L) 24VDC /TR(+) ON(L) 24VDC TR ON(L) 24VDC TRMO-I TRMO-V BTR-D/A DTS-D/A Signal Direction MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS Trigger Level Level Level Level Level Level Level Level Level Level Level High Level TTL 24V 24V 24V 24V 24V 24V * * * * Low Level TTL 0V 0V 0V 0V 0V 0V * * * * Analog Analog Analog Analog Note

Chapter 4. Circuit Diagrams 321

MCU REG. CLUTCH, REG. SENSOR, PICK UP SOLENOID, and AUX TRAY NO-PAPER SENSOR
MCU
P/J131

REGISTRATION CLUTCH ASSEMBLY


3 2 1

4 3 2 1 24VDC REG. ON(L) 24VDC

P/J13
1 2 3 4 5 6 7 8

P.UP SG /REGIN(TTL)

REGISTRATION SENSOR

P/J132

P/J135 P/J935

FEED SOLENOID (PICK UP SOLENOID)

1 2

2 1

24VDC PICK UP ON(L) 24VDC

9 10

TRANSPORT CHUTE ASSEMBLY


P/J134 P/J937 P/J137
1 2 3 3 2 1 P.UP SG /NO PAPER0(TTL)

AUX TRAY NO PAPER SENSOR

3 2 1

hc2m999F

Chapter 4. Circuit Diagrams 322

Signal names for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path
Signal Name REG. ON(L) 24VDC /REG. IN (TTL) /NO PAPER0 (TTL) PICK UP ON(L) 24VDC Description Registration Clutch control signal. The Registration Clutch is activated when this signal is Low, and deactivated when High. Signal from the Registration Sensor. This signal is Low when the Registration Sensor is activated. Signal from the Aux Tray No-Paper Sensor (Front Tray). This signal is Low when the SI No-Paper Sensor is activated. Pick Up Solenoid control signal. The Pick Up Solenoid is activated when this signal is Low, and deactivated when High.

Chapter 4. Circuit Diagrams 323

Pin numbers and voltage levels for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path
Signal Direction M: MCU, RC: Reg. Clutch RS: Reg. Sensor AT: Aux Tray No-Paper Sen. P13 2 5 8 10 P131-1 P132-1 P137-1 P935-1 Signal Name REG. ON(L) 24VDC /REG. IN (TTL) /NO PAPER0 (TTL) PICK UP ON(L) 24VDC FS: Feed Solenoid MRC MRS MAT MFS Trigger Level Level Level Level High Level TTL 24V 24V 24V Low Level TTL 0V 0V 0V

Chapter 4. Circuit Diagrams 324

MCU FEEDER1 PWB FEED SOLENOID, CST NO-PAPER SENSOR, and ELECTROMAGNETIC CLUTCH
ELECTROMAGNETIC CST NO PAPER FEED SOLENOID SENSOR CLUTCH

P/J 205 P/J 206

3 2 1
/NO PAPER1 (TTL)

1 2 P/J 204 2 1 P/J

4 3 2 1
P.UP SG

904

/TURN ON (L) 24VDC

P/J203

1 2 3 4 5 6 7 8 9

MCU

P/J20
PSIZE3 (TTL) A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 PSIZE1 (TTL) /FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK 5VDC 24VDC RTN SG OPTION /NO PAPER2 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) N.C.

P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 SW4 SW3 SW2 SW1 PAPER SIZE SWITCH SIZE SENSE 24VDC

/FEED1 ON(L) 24VDC

24VDC

24VDC

A B Y C
W

5VDC

P207 P/J202
1 2 N.C. 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

F
24VDC

A10 A9

A8 A7 A6 A5

A4 A3 A2 A1 B10 B9 B8

D X Z F

B7 B6 B5 B4

B A

B3 B2 B1

Z Y X w

FEEDER1

5VDC

5VDC
hc2m800F

Chapter 4. Circuit Diagrams 325

Signal names for the MCU FEEDER1 PWB path


Signal Name PSIZE3 (TTL) Description Selects the Paper Size Switches of Feeder 3. When this signal is High, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT. Selects the Paper Size Switches of Feeder 1. When this signal is High, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 1 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT. Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) is activated when this signal is Low, and deactivated when High. Feed Solenoid 1 control signal. The Feed Solenoid 1 (Feed Solenoid of the Feeder 1) is activated when this signal is Low, and deactivated when High. Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 1, 2 or 3 signal. This signal is Low when the Paper Size Switch 3 is activated. Signal from the Paper Size Switch 1 of the Feeder selected with PSIZE 1, 2 or 3 signal. This signal is Low when the Paper Size Switch 1 is activated. Signal from the No Paper Sensor 3 (No Paper Sensor of the Feeder 3). This signal is Low when the No Paper Sensor 3 is activated. Signal from the No Paper Sensor 1 (No Paper Sensor of the Feeder 1). This signal is Low when the No Paper Sensor 1 is activated. Signal that indicates the Feeder Conguration. Reserved for option. Signal from the No Paper Sensor 2 (No Paper Sensor of the Feeder 2). This signal is Low when the No Paper Sensor 2 is activated. Signal from the Paper Size Switch 2 of the Feeder selected with PSIZE 1, 2 or 3 signal. This signal is Low when the Paper Size Switch 2 is activated.

PSIZE1 (TTL)

/FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK OPTION /NO PAPER2 (TTL) /SIZE 2BIT (TTL)

Chapter 4. Circuit Diagrams 326

Signal Name /SIZE 4BIT (TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL)

Description Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 1, 2 or 3 signal. This signal is Low when the Paper Size Switch 4 is activated. Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) is activated when this signal is Low, and deactivated when High. Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutch is activated when this signal is Low, and deactivated when High. Selects the Paper Size Switches of Feeder 2. When this signal is High, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT.

Chapter 4. Circuit Diagrams 327

Pin numbers and voltage levels for the MCU FEEDER1 PWB path
Signal Direction P20 A1 A2 A3 A4 A5 A6 A7 A8 A9 B3 B4 B6 B7 B8 B9 B10 P201 A11 A10 A9 A8 A7 A6 A5 A4 A3 B10 B9 B7 B6 B5 B4 B3 Signal Name PSIZE3 (TTL) PSIZE1 (TTL) /FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK OPTION /NO PAPER2 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) M: MCU, F: Feeder1 MF MF MF MF MF MF MF MF MF MF MF MF MF MF MF MF Trigger Level Level Level Level Level Level Level Level Level Level Level Level Level Level Level Level TTL TTL TTL 24V TTL TTL TTL TTL TTL 0V TTL TTL High Level TTL TTL 24V 24V TTL TTL TTL TTL * Low Level TTL 0V 0V 0V TTL TTL TTL TTL * Analog Note

Chapter 4. Circuit Diagrams 328

MCU MAIN MOTOR


MCU

MAIN MOTOR
24VDC

P/J16
RTN /MOT REV (TTL) MOT ALM (TTL) /MAIN MOT(TTL)

1 2 3 4 5

hc2m801F

Chapter 4. Circuit Diagrams 329

Signal names for the MCU Main Motor path


Signal Name /MOT REV (TTL) Description Control signal to switch the direction of the rotation of the Main Motor between Normal and Reverse. Low: Reverse direction, High: Normal direction MOT ALARM (TTL) /MAIN MOT (TTL) Main Motor monitor signal. Goes Low when the rotation of the Main Motor is abnormal. Main Motor Control Signal to switch the Main Motor on and off.

Pin numbers and voltage levels for the MCU Main Motor path
P16 3 4 5 Signal Name /MOT REV (TTL) MOT ALARM (TTL) /MAIN MOT (TTL) Signal Direction MCUMain Motor MCUMain Motor MCUMain Motor Trigger Level Level Level High Level Low Level TTL TTL TTL TTL TTL TTL

Chapter 4. Circuit Diagrams 330

MCU TONER SENSOR


MCU

TONER SENSOR
P/J221
1 2 3 4

P/J 922
1 2 3 4

P/J 222
4 3 2 1

24VDC N.C. SG /NO TONER (TTL)

P/J22
1 2 3 4

hc2m802F

Signal names for the MCU Toner Sensor path


Signal Name /NO TONER (TTL) Description Signal from the Toner Sensor. Goes Low when toner is low in the EP Cartridge.

Pin numbers and voltage levels for the MCU Toner Sensor path
P22 4 P222 1 P922 4 P221 4 Signal Name /NO TONER (TTL) Signal Direction MCUToner Sensor Trigger Level High Level TTL Low Level TTL

Chapter 4. Circuit Diagrams 331

MCU DUPLEX I/F PWB FUSER COVER SWITCH or MCU FUSER COVER SWITCH
J182 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 P/J 18
18 17 16 15 14 13 12

P/J 190
2 1

P/J 180
1 2

11 /FCOVER OPEN (TTL) 10 9 8 7 6 5 4 3 2 1

COVER SWITCH

DUPLEX I/F PWB

MCU

OR
P/J190
2 1

18 17 16 15 14 13 SG 12 11 10 9

COVER SWITCH

/FCOVER OPEN (TTL)

8 7 6 5 4 3 2 1

hc2m803F

Chapter 4. Circuit Diagrams 332

Signal names for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path
Signal Name /FCOVER OPEN (TTL) Description Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch is deactivated (the Fuser Cover is open).

Pin numbers and voltage level for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path
P18 9 P180 1 P190 2 Signal Name /FCOVER OPEN (TTL) Signal Direction MCUFuser Cover Switch Trigger Level High Level TTL

Signal names for the MCU FUSER COVER SWITCH path


Signal Name /FCOVER OPEN Description Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch is deactivated (the Fuser Cover is open).

Pin numbers and voltage level for the MCU FUSER COVER SWITCH path
P18 8 P190 1 Signal Name /FCOVER OPEN (TTL) Signal Direction MCUFuser Cover Switch Trigger Level High Level TTL

Chapter 4. Circuit Diagrams 333

CONTROLLER CONTROL PANEL


P/J411
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 /LED 4 (TTL) /LED 3 (TTL) /LED 2 (TTL) /LED 1 (TTL) /KEY 1 (TTL) /KEY 2 (TTL) /KEY 3 (TTL) /KEY 4 (TTL) /KEY 5 (TTL) /KEY 6 (TTL) /KEY 7 (TTL) /KEY 8 (TTL) DB7 (TTL) DB6 (TTL) DB5 (TTL) DB4 (TTL) E (TTL) RS (TTL) 5VDC SG

P/J421
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
hc2m804F

CONTROLLER

CONTROL PANEL

P412

Chapter 4. Circuit Diagrams 334

16X2 TN LCD MODULE

To Controller

+5v

P421- 4 P421- 3 P421- 8 P421- 7 P421- 6 P421- 5 P421- 9 P421-10 P421-11 P421-12 P421-13 P421-14 P421-15 P421-16

E RS DB7 DB6 DB5 DB4 KEY8 KEY7 KEY6 KEY5 KEY4 KEY3 KEY2 KEY1

10K

P421- 2 P421- 1

+5v SG

DB3 DB2 DB1 DB0 R/W VSS V0 VDD

+5V

0.1 + CER

47 ALM

Buffer

Attention Cancel Print

Online
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8

Continue

Enter

*
+

Menu

Item

Value

150

150

150

P421-17 P421-18 P421-19 P421-20

LED1 LED2 LED3 LED4


hc2m941F

Signal names for the Controller Control Panel path


Signal Name /LED1 (TTL) /LED4 (TTL) /KEY1 (TTL) /KEY8 (TTL) DB4 DB7 (TTL) E (TTL) Description LED switching signals. When these signals goes Low, the corresponding LEDs illuminate. Key signals. When a key is pressed, the corresponding KEY signal goes Low. 4-bit data signals. LCD enabling signal. Low: Disable, High: Enable

150

LED1

LED2

LED3

LED4

Shift

Chapter 4. Circuit Diagrams 335

Signal Name RS (TTL)

Description Register selecting signal which selects the command registers or the data registers. Low: Command registers, High: Data registers

Pin numbers and voltage levels for the CONTROLLER CONTROL PANEL path
Signal Direction C: Controller P411 14 512 1316 17 18 P421 2017 169 85 4 3 Signal Name /LED4 (TTL) /LED1 (TTL) /KEY1 (TTL) /KEY8 (TTL) DB7(TTL) DB4 (TTL) E (TTL) RS (TTL) CP: Control Panel CCP CCP CCP CCP CCP Trigger Level Level Level Level Level High Level TTL TTL TTL TTL TTL

Chapter 4. Circuit Diagrams 336

CONTROLLER MCU and LVPS


MCU
5VDC

P/J31
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 /TPRINT /PRFD /CCLK /VDO +5V /CBSY /STA /TOP /PPRDY SG SG SG SG /CMD /CPRDY /START /PCLK /SBSY /RDY /BD

P411

CONTROLLER

P23
1 2 SG /TPRINT (TTL)

P/J412

P/J126

LVPS

1 2

5VDC SG
hc2m805F

Chapter 4. Circuit Diagrams 337

Signal names for the Controller MCU path


Signal Name /TPRINT (TTL) Description Test print. Printing test starts when this signal goes Low.

Pin numbers and voltage levels for the Controller MCU path
P/J31 A1 Signal Name /TPRINT Signal Direction MCUController Trigger Level High Level TTL Low Level TTL

Chapter 4. Circuit Diagrams 338

Signals between the Controller and the MCU


The table below lists the signals that are used between the Controller and the MCU.
PIN A9 A8 A7 A6 A4 SIGNAL /PPRDY /TOP /STA /CBSY /VDO DIRECTION MCUController MCUController MCUController MCUController MCUController DESCTIPTION Printer Power Ready: Goes Low when the printer is powered on and completes initialization. The printer is in ON-LINE mode. Top of Paper: Vertical synchronization signal. Status: The MCU sends a Status serially in synchronism with /PCLK (/CCLK when the Controller requests the MCU to use it). Command Busy: The Controller holds this signal Low while sending a Command. Video: The Controller sends print data to the MCU, synchronizing the beginning of each page and each line (raster line) of the print data with /TOP and /BD, respectively. The transmission rate depends on the print resolution. v 300dpi: 4.41769 MHz/480dpi: 11.30930 MHz v 360dpi: 6.36148 MHz/600dpi: 17.67078 MHz v 400dpi: 7.85368 MHz/800dpi: 31.41472 MHz Controller Clock: Clock signal that is supplied by the Controller and used for synchronous transmission of a Command by the Controller. The MCU uses this clock signal for transmission of a Status when requested to use it by the Controller. Prefeed: When the MCU receives this signal, it feeds a sheet of paper to just before the Registration Sensor (pre-fed position), and waits for /START.

A3

/CCLK

MCUController

A2

/PRFD

MCUController

Chapter 4. Circuit Diagrams

339

PIN B10

SIGNAL /BD

DIRECTION MCUController

DESCTIPTION Beam Detect: Horizontal synchronization signal. The Controller begins to send the video data for one scan line when it receives this signal. /BD is sent at the following time intervals. v 300 dpi: 930.4 ms/480 dpi: 581.5 ms v 360 dpi: 775.3 ms/600 dpi: 465.2 ms v 400 dpi: 697.8 ms/800 dpi: 348.9 ms Ready: The MCU holds this signal Low when it can accept /PRFD and /START. When /RDY is High, /PRFD and /START are ignored. The MCU raises /RDY High when the printer is in one of the following states: 1. Call 2. Pause/Diagnostic 3. Wait 4. Misprint 5. /PPRDY at High

B9

/RDY

MCUController

B8 B7 B6

/SBSY /PCLK /START

MCUController MCUController MCUController

Status Busy: The MCU holds this signal Low when it is sending a Status. Printer Clock: Clock signal that the MCU supplies and uses for synchronized transmission of a Status. START: Orders the printer to start the print operation. This signal is valid only when /RDY is Low.

Chapter 4. Circuit Diagrams

340

PIN B5

SIGNAL /CPRDY

DIRECTION MCUController

DESCTIPTION Controller Power Ready: Goes Low when the Controller is powered on and completes initialization. When this signal goes High, the printer resets to the powered-on state. v Printer stateStandby (ROS: Off, Fuser: On) When the printer is in the Printing state or the Print Ready state, the printer returns to the Standby state immediately or after the print operation is completed. When in the Pause state (ROS: Off, Fuser: Off), the printer returns to the Standby state except when the Fan is stopped. (continued)

B5

/CPRDY

MCUController

v ResolutionHigher resolution When the printer has two resolutions and the lower resolution is selected, the resolution returns to the Higher resolution. v Paper size mismatch detectionEnabled v Fuser temperatureNormal temperature When the high temperature for thick paper is selected, the fuser temperature returns to the normal temperature.

B4

/CMD

MCUController

Command: The Controller sends a Command serially in synchronism with /CCLK.

Chapter 4. Circuit Diagrams 341

MCU Feeder PWB Feeder PWB Feeder PWB Feed Solenoid, No Paper Sensor, and Electromagnetic Clutch
2nd Tray (Optional)
FEEDER ASSY
ELECTROMAGNETIC CST NO PAPER CLUTCH AUX. SENSOR FEED SOLENOID

P/J 1 2 3 4 906 P/J 206 4 3 2 1


TURN ON (L) 24VDC

P/J 205 3 2 1

1 2 204 2 1 P/J
/ FEED 2 ON (L) 24VDC

P/J

/ NO PAPER 2 (TTL)

904

P.UP

SG

1st Tray
MCU PWB
P/J20
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11

P/J203 1 2 3 4 5 6 7 8 9

FEEDER PWB
P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

P/J207
A

P/J201
N.C. PSIZE2 (TTL) N.C. /FEED2 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) N.C. /NO PAPER2 (TTL) FEEDER CHECK SVDC 24VDC RTN SG OPTION /NO PAPER3 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL) N.C.
5VDC A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 24VDC

24VDC

24VDC

P207 P/J202
M
A10 A9 N.C. 1 2 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

P/J202

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

G H
24VDC

F
B E

A10 A9 A8 A7 A6

K Y I W J

A8 A7 A6 A5 A4 A3 A2 A1 B10 B9 B8

C D

A5 A4 A3 A2 A1 B10 B9 B8

B7 B6 B5 B4

J X Z K M

B7 B6 B5 B4

E F

B A

B3 B2 B1

H G

B3 B2 B1

SW4 SW3 SW2 SW1 PAPER SIZE SWITCH SIZE SENSE

Z Y X w

5VDC

5VDC

FEEDER PWB

hc2m816F

Chapter 4. Circuit Diagrams 342

3rd Tray (Optional)

FEEDER ASSY

ELECTROMAGNETIC CST NO PAPER CLUTCH AUX. SENSOR

FEED SOLENOID

P/J 1 2 3 4 906 P/J 206 4 3 2 1


TURN ON (L) 24VDC

P/J 205 3 2 1

1 2 204 2 1 P/J
/ FEED 3 ON (L) 24VDC

P/J

/ NO PAPER 3 (TTL)

904

P.UP

SG

1st Tray
MCU PWB
P/J20
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11

2nd Tray (Optional)


FEEDER PWB
P/J20 P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

P/J203 1 2 3 4 5 6 7 8 9

FEEDER PWB
P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1

P/J207
A
F B

P/J201
N.C. PSIZE2 (TTL) N.C. /FEED1 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) N.C. /NO PAPER1 (TTL) FEEDER CHECK SVDC 24VDC RTN SG OPTION /NO PAPER2 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) N.C.
5VDC A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 24VDC

24VDC

24VDC

P207 P/J202
M
A10 A9 N.C. 1 2 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

A
F B

A1 A2 A3

P/J202
A10 A9

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

G H
24VDC

A4 A5 A6

A8 A7 A6

K Y I W J

A8 A7 A6 A5 A4 A3 A2 A1 B10 B9 B8

C D

A7 A8 A9 A10 A11 B1 B2 B3

C D

A5 A4 A3 A2 A1 B10 B9 B8

B4 B5 B6 B7

B7 B6 B5 B4

J X Z K M

B7 B6 B5 B4

B8 B9

B3 B2

H G

B3 B2 B1

B10 B11

B1

SW4 SW3 SW2 SW1 PAPER SIZE SWITCH SIZE SENSE

Z Y X w

5VDC

5VDC

FEEDER PWB

hc2m807F

Chapter 4. Circuit Diagrams 343

Signal names for the Feeder PWB Feeder PWB path


Signal Name PSIZE2 (TTL) Description Selects the Paper Size Switches of Feeder 2. When this signal is HIGH, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT. Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) is activated when this signal is LOW, and deactivated when HIGH. Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 2 or 3 signal. This signal is LOW when the Paper Size Switch 3 is activated. Signal from the Paper Size Switch 1 of the Feeder selected with the PSIZE2 or 3 signal. This signal is LOW when the Paper Size Switch 1 is activated. Signal from the No Paper Sensor 2 (No Paper Sensor of the Feeder 2). This signal is Low when the No Paper Sensor 2 is activated. Signal that indicates the Feeder Conguration. Signal from the No Paper Sensor 3 (No Paper Sensor of the Feeder 2). This signal is Low when the No Paper Sensor 3 is activated. Signal from the Paper Size Switch 2 of the Feeder selected with PSIZE 2 or 3 signal. This signal is LOW when the Paper Size Switch 2 is activated. Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 2 or 3 signal. This signal is LOW when the Paper Size Switch 4 is activated. Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) is activated when this signal is LOW, and deactivated when HIGH. Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutch is activated when this signal is LOW, and deactivated when HIGH. Selects the Paper Size Switches of Feeder 3. When this signal is HIGH, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT.

/FEED2 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER2 (TTL) FEEDER CHECK /NO PAPER3 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL)

Chapter 4. Circuit Diagrams 344

Pin numbers and voltage levels for the Feeder PWB (Feeder1) Feeder PWB (Feeder2) path
Signal Direction P202 (Feeder1) A10 A8 A7 A6 A4 A3 B7 B5 B4 B3 B2 B1 P201 (Feeder2) A10 A8 A7 A6 A4 A3 B9 B7 B6 B5 B4 B3 F1: Feeder1 Signal Name PSIZE2 (TTL) /FEED2 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER2 (TTL) FEEDER CHECK /NO PAPER3 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL) F2: Feeder2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 Trigger Level Level Level Level Level Level Level Level Level Level Level Level High Level TTL 24V TTL TTL TTL * TTL TTL TTL 24V TTL TTL Low Level TTL 0V TTL TTL TTL * TTL TTL TTL 0V TTL TTL Analog

Note

*: Refer to the description of the detection of the feeder conguration on the next page.

Chapter 4. Circuit Diagrams 345

Pin numbers and voltage levels for the Feeder PWB (Feeder2) Feeder PWB (Feeder3) path
Signal Direction P202 (Feeder2) A10 A8 A7 A6 A4 A3 B5 B4 B3 B2 P201 (Feeder3) A10 A8 A7 A6 A4 A3 B7 B6 B5 B4 F2: Feeder2 Signal Name PSIZE3 (TTL) /FEED3 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) FEEDER CHECK /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) F3: Feeder3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 Trigger Level Level Level Level Level Level Level Level Level Level High Level TTL 24V TTL TTL TTL * TTL TTL 24V TTL Low Level TTL 0V TTL TTL TTL * TTL TTL 0V TTL Analog

Note

*: Refer to the description of the detection of the feeder conguration on the next page.

Chapter 4. Circuit Diagrams 346

Detection of the Feeder conguration through the FEEDER CHECK signal


When no optional Feeder is attached, 5 VDC is divided by the resistance RM on the MCU PWB and the resistance RF on the Feeder PWB of the Feeder 1, and the voltage across the resistance RM appears on the FEEDER CHECK signal. When one or two optional Feeders are added, the resistance RF on the Feeder PWB of the added Feeder or Feeders is connected in parallel with the resistance RF of the Feeder 1, and the voltage across the resistance RM changes according to the number of optional Feeders added. Therefore, the Feeder conguration can be detected from the voltage of the FEEDER CHECK signal.

TRAY 1
MCU PWB
5VDC

TRAY 2
FEEDER PWB

TRAY 3
FEEDER PWB

FEEDER PWB

RF FEEDER CHECK (TTL)

RF

RF

Detection Circuit
RM

SG

hc2m814F

Chapter 4. Circuit Diagrams 347

Feeder Conguration Feeder1 (standard Feeder) not connected Feeder1 only One optional Feeder added Two optional Feeders added

Feeder 1

Feeder 2

Feeder 3

Voltage (Nominal) 0 VDC

O O O O O O

1.60 VDC 2.42 VDC 2.93 VDC

Chapter 4. Circuit Diagrams 348

MCU Duplex I/F PWB Duplex PWB and Fuser Cover Switch Duplex PWB Dup Stack Sensor, Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor
COVER SWITCH P/J192
1 2 3

P.UP

P/J184
5VDC 1 2 P/J190
1 2 3 4 5 6

SG / FULL (TTL)

DUP STACK SENSOR

SG / DUP COV 1 (TTL)

P/J193
2 1

DUP COVER SWITCH 1

1 P/J180

/ DUP COV 2 (TTL) / DUP COV (TTL)

P/J198
2 1

DUPLEX I/F PWB


P/J182
1 9 2 10 3 11 4 12 5 13 6 14 7 15 8

DUP COVER SWITCH 2

DUP B DUP / A DUP A DUP / B RTN SG 24VDC N.C. / DUP COVER (TTL) 5VDC / FULL (TTL) / OCT REV (TTL) / OCT ON (TTL) / DUP SNS (TTL)

P/J183
1 2 3 4 5 6 7 8 9 10 11 12 13 14

P/J187
1

P/J197
A B 24VDC 24VDC /A /B
1 2 3 4 5 6

DUPLEX MOTOR CONTROL

2 3 4 5 6 7 8

M
P/J195
1 2

DUPLEX MOTOR

/ DUP SNS (TTL) SG

DUPLEX PASS SENSOR

P/J186
1

P/J196
MOT + MOT 1 2

OFFSET MOTOR CONTROL

OFFSET MOTOR

5VDC 24VDC

1 2

3 4 5 6

7 8

9 10 11 12 13 14 15 16 17 18

P/J18

MCU PWB

DUPLEX PWB DUPLEX UNIT


hc2m826F Chapter 4. Circuit Diagrams 349

Signal names for the Duplex I/F PWB Duplex PWB path
Signal Name DUP B DUP /A DUP A DUP /B /DUP COVER (TTL) Description Duplex Motor exciting signal. Duplex Motor exciting signal. Duplex Motor exciting signal. Duplex Motor exciting signal. Signal from the Dup Cover Switches 1 and 2. This signal is LOW when both the Dup Cover Switches 1 and 2 are closed and High when the Dup Cover Switch1 or the Dup Cover Switch2 is open. Signal through the Dup Stack Sensor. This signal is LOW when the Dup Stack Sensor is activated by the stack of delivered printed sheets higher than the predetermined height. This signal is also used to detect whether the Duplex Unit is installed when printer power is switched on. /OCT REV (TTL) Control signal to switch the direction of rotation of the Offset Motor between Normal and Reverse. LOW: Reverse direction, HIGH: Normal direction /OCT ON (TTL) /DUP SNS (TTL) Offset Motor Control Signal to switch the Offset Motor on and off. Signal from the Duplex Pass Sensor. This signal is LOW when the Duplex Pass Sensor is activated by the paper.

/FULL

Chapter 4. Circuit Diagrams 350

Pin numbers and voltage levels for the Duplex I/F PWB Duplex PWB path
Signal Direction DIF: Dup I/F PWB P182 1 9 2 10 5 6 14 7 15 P183 1 2 3 4 9 11 12 13 14 Signal Name DUP B DUP /A DUP A DUP /B /DUP COVER (TTL) /FULL /OCT REV (TTL) /OCT ON (TTL) /DUP SNS (TTL) D: Duplex PWB DIFD DIFD DIFD DIFD DIFD DIFD DIFD DIFD DIFD Trigger Level Level Level Level Level Level Level Level Level TTL * TTL TTL TTL TTL 0V TTL TTL TTL High Level

Low Level

* Refer to the description of the Duplex unit detection on the next page.

Signal names for the Duplex PWB Offset Motor path


Signal Name MOT+, MOTDescription Offset Motor drive power. Normal rotation: When MOT+ is 24 VDC and MOT- is 0 VDC. Reverse rotation: When MOT+ is 0 VDC and MOT- is 24 VDC.

Chapter 4. Circuit Diagrams 351

Pin numbers and voltage levels for the Duplex PWB Offset Motor path
Signal Direction D: Duplex PWB P186 1 2 P196 1 2 Signal Name MOT+ MOTOM: Offset Motor D OM D OM Trigger Level Level High Level 24 VDC 24 VDC Low Level 0V 0V

Chapter 4. Circuit Diagrams 352

HCF LVPS Components, HCF LVPS FEEDER PWB


LVPS
LIFT UP MOTOR CONTROL P/J:XS1 10 9 1 2 5 6 3 4 7 8 P/J:XS2 12 11 25 26 P/J:XS3 P/J:XS4 RXD 14 1 TXD 16 2 SG 12 3 SG 13 4 FEEDER CHECK 9 5 3 4 5 FEED MOTOR CONTROL 1 2 6 7 8 22 23 24 9 10 13 14 15 TRANSPORT MOTOR CONTROL 18 19 20 21 16 17 27 28 MAIN SWITCH
GND GND DC21 DC22 DC22 SWHD SG SWPL(TTL) SG SWPSZ(TTL) FG

CPU

P/J:M1 (+) (-) P/J:S2 1 3 P/J:S1 1 3 P/J:S3 1 3 P/J:S7 2 1 P/J:S11 1 3 P/J:P1 3 2 1 5 4 P/J:P2 1 2 3 P/J:S10 1 2 3 P/J:S6 1 2 P/J:S8 1 2 3 P/J:M2 1 2 3 4 P/J:S9 1 2 P/J:S12 1 2

LIFT UP MOTOR LOWER POSITION SENSOR

NEAR EMPTY SENSOR

SIZE SENSOR

DC21 SWHU1 SWHU1 SWHU2 +5VDC LSPE(TTL) SG DC11 DC12 +5VDC ENCOD(TTL) SG +5VDC LSPL(TTL) SG SWCPR(TTL) SG +5VDC LSPEX(TTL) SG SM1 SM2 SM3 SM4 SWDO1(TTL) SG SWDO1(TTL) SWDO(TTL)

TRAY SET SENSOR 2

UPPER LIMIT SENSOR

NO PAPER SENSOR

Base Engine or 2ND TRAY

FEED MOTOR

ENCODER

SG

PAPER LEVEL SENSOR

TRAY SET SENSOR 1

SENSOR

TRANSPORT MOTOR

LEFT HAND COVER OPEN SWITCH RIGHT HAND COVER OPEN SWITCH

AC to DC

SERVICE CONNECT

AC INLET

hc2m089F

This is an internal wiring of the FEED ROLLER KIT, therefore the P/J No. and Pin No. are omitted.

Chapter 4. Circuit Diagrams 353

Signal names for the HCF LVPS Components


Signal Name DC21, DC22 Description DC21, DC22 Elevator Motor drive power Elevator rotation: When DC21 is 0VDC and DC22 is more then 22VDC. Lift down rotation: When DC21 is more then 22VDC and DC22 is 0VDC. SWHD SWITCH HAZARD DOWN This switch interrupts the motor current if the elevator is in the down position (ll position). SWPL (TTL) SWITCH PAPER LOW This signal indicates the Paper low stack. LSPE (TTL) LIGHT SENSOR PAPER END This signal indicates if the last sheet fed. ENCOD (TTL) ENCODER SIGNAL This signal controls the Feed Motor. It works as speed regulator. DC11, DC12 DC11, DC12 Feed Motor drive power, 0 / 24VDC (PWM SIGNAL) LSPL (TTL) LIGHT SENSOR PAPER LEVEL This signal shows if the paper stack is in feed position. SWCPR (TTL) SWITCH CARRIAGE PRESENT This signal indicates if the carriage is in or out.

Chapter 4. Circuit Diagrams 354

Signal Name LSPEX (TTL)

Description LIGHT SENSOR PAPER EXIT This signal indicates that a paper is in the transport.

SM1

TRANSPORT MOTOR/A Transport Motor exciting signal.

SM2

TRANSPORT MOTOR A Transport Motor exciting signal.

SM3

TRANSPORT MOTOR/B Transport Motor exciting signal.

SM4

TRANSPORT MOTOR B Transport Motor exciting signal.

SWDO (TTL) SWDO1 (TTL) SWHU1 SWHU2 SWPSZ (TTL)

SWITCH DOOR OPEN This signal indicates an open rear cover. SWITCH HAZARD UP This safety switch interrupts the motor current if the Paper Level Sensor does not work and the elevator moves up too much. SWITCH PAPER SIZE This signal displays the used paper size in the HCF.

Chapter 4. Circuit Diagrams 355

Signal names for the HCF LVPS FEEDER PWB


Signal Name TXD Description TRANSMITTED DATA Data connection Base Engine to HCF. RXD RECEIVED DATA Data connection HCF To Base Engine. FEEDER CHECK FEEDER CHECK Signal that indicates the Feeder / HCF Conguration.

Chapter 4. Circuit Diagrams 356

Pin numbers and voltage levels for the HCF LVPS Components
P: XS1-1 XS1-2 XS1-3 XS1-4 XS1-5 XS1-6 XS1-7 XS1-8 XS1-9 XS1-10 XS2-1 XS2-2 XS2-3 XS2-4 XS2-5 XS2-6 XS2-7 XS2-8 XS2-9 P1-5 P1-4 P1-3 P1-2 P1-1 P2-1 P2-2 P2-3 S6-1 P: M1-(+) M1-(-) S1-1 S1-3 S2-1 S2-3 S3-1 S3-3 Signal Name DC21 DC22 SG SWPL (TTL) DC22 SWHD SG SWPSZ (TTL) SG SG DC11 DC12 +5V LSPE (TTL) SG +5V ENCOD (TTL) SG SWCPR (TTL) Signal Direction Floating Signal (see note 1) Floating Signal (see note 1) Power Near Empty Sensor LVPS Floating Signal (see note 1) Floating Signal (see note 1) Power Paper Size Sensor LVPS Power Power LVPS Feed Motor LVPS Feed Motor Power No Paper Sensor LVPS Power Power Encoder LVPS Power Tray Set Sensor 1 LVPS Trigger LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL High Level 0V 24V 0V TTL 24V 24V 0V TTL 0V 0V 24V 24V 5V TTL 0V 5V TTL 0V TTL TTL TTL TTL 0V (see note 2) 0V (see note 2) TTL TTL 0V 0V Low Level 24V 0V

Chapter 4. Circuit Diagrams 357

P: XS2-10 XS2-11 XS2-12 XS2-13 XS2-14 XS2-15 XS2-16

P: S6-2 S7-1 S7-2 S8-1 S8-2 S8-3 S9-1

Signal Name SG SWHU1 DC21 +5V LSPEX (TTL) SG SWDO1

Signal Direction Power Floating Signal (see note 1) Floating Signal (see note 1) Power Sensor LVPS Power Left Hand Cover Open Switch Right Hand Cover Open Switch Power LVPS Transport Motor LVPS Transport Motor LVPS Transport Motor LVPS Transport Motor Power Paper Level Sensor LVPS Power Floating Signal (see note 1) Floating Signal (see note 1)

Trigger LEVEL LEVEL LEVEL LEVEL

High Level 0V 24V 24V 5V TTL 0V TTL

Low Level

0V 0V

TTL

TTL

XS2-17 XS2-18 XS2-19 XS2-20 XS2-21 XS2-22 XS2-23 XS2-24 XS2-25 XS2-26

S9-2 M2-1 M2-2 M2-3 M2-4 S10-1 S10-2 S10-3 S11-1 S11-3

SG SM1 SM2 SM3 SM4 +5V LSPL (TTL) SG SWHU1 SWHU2

LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL

0V 24V 24V 24V 24V 5V TTL 0V 24V 24V 0V 0V TTL 0V (see note 3) 0V (see note 3) 0V (see note 3) 0V (see note 3)

Chapter 4. Circuit Diagrams 358

P: XS2-27

P: S12-1

Signal Name SWDO1

Signal Direction Left Hand Cover Open Switch Right Hand Cover Open Switch Right Hand Cover Open Switch LVPS

Trigger LEVEL

High Level TTL

Low Level TTL

XS2-28

S12-2

SWDO

LEVEL

TTL

TTL

Notes: 1. This signal is used to stop the Elevator Motor when it is not responding. It is connected to the Drive Power cable and the Serial port (no direction). 2. PWM (Pulse Width Modulation) Signal 3. Rectangle Signal

Chapter 4. Circuit Diagrams 359

Chapter 5. Locations
Quick Path . . . . . . . . . . . . . Covers and Assemblies . . . . . . Electrical Components . . . . . . . Clutches, Solenoids, Motors, and Connectors . . . . . . . . . . . Printed Wiring Boards (PWBs). . Sensors . . . . . . . . . . . . . Switches . . . . . . . . . . . . . Mechanical and Miscellaneous . . . . . . . . . . . Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 .362 .364 .364 .367 .380 .384 .386 .390

Copyright IBM Corp. 1998

360

Quick Path
To... Assemblies Clutches Connectors Covers Fans Mechanical Motors Paper Path Printed Wiring Boards (PWBs) / Power Supplies Sensors Solenoids Switches Location Tables with Links to Illustrations, to the Parts Catalog, to Wiring and Pinout Diagrams, and to Removals Table 59 on page 362 Table 60 on page 364 Table 61 on page 367 Table 59 on page 362 Table 60 on page 364 Table 65 on page 390 Table 60 on page 364 Figure 23 on page 392 Table 62 on page 380 Table 63 on page 384 Table 60 on page 364 Table 64 on page 386

Chapter 5. Locations 361

Covers and Assemblies


Table 59. Assemblies
Unit Cover or Assembly Operator Panel Top Cover Tray 1 Auxiliary Tray Printer Fuser Cover Rear Cover Serial Number Power Cord Socket Power Switch Side Cover Duplex Duplex Unit Duplex Covers Trays Tray 2/3 2000-Sheet Input Drawer Figure Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 Fig. 5, p. 363 124, p. 572 124, p. 572 110, p. 548 30, 31, p. 652, 655 30-5, 30-6, p. 652 20, 21, p. 697, 700 40, 41, 42, p. 774, 776, 778 Parts Catalog Asm. Index 118, p. 548 114, p. 548 2, p. 550 5, p. 557 81, p. 564 35, p. 553

Chapter 5. Locations 362

Operator panel

Top cover

Fuser cover

Printer controller board


X12345

Side cover
Power switch

500-sheet paper tray (Tray 1)

Auxiliary tray

Rear cover Serial number


Power cord socket

Duplex unit (optional)

Duplex covers

500-sheet paper trays (Tray 2/Tray 3) (optional)

2000-sheet input drawer (optional)


hc2m221F

Figure 5. Covers and Assemblies

Chapter 5. Locations 363

Electrical Components Clutches, Solenoids, Motors, and Fans


Table 60. Clutches, Solenoids, Motors, and Fans
Unit Clutch, Solenoid, Motor, or Fan CL1 Registration Clutch CL2 Electromagnetic (Turn) Clutch Printer SL1 Feed Solenoid SL2 Pick Up Solenoid Fan Main motor Trays Figure / Reference Fig. 6, p. 365 / 6 Fig. 6, p. 365 / 5 Fig. 6, p. 365 / 4 Fig. 6, p. 365 / 2 Fig. 6, p. 365/ 1 Fig. 6, p. 365/ 3 Parts Catalog Asm. Index 109, p. 570 49, p. 555 48, p. 555 617, p. 559 123, p. 575 106, p. 570 2119, p. 700 2118, p. 700 3021, p. 652 3123, p. 655 4110, p. 776 4228, p. 778 4221, p. 778 Wiring Diagram p. 322 p. 325 p. 325 p. 322 p. 311 p. 329 p. 342 p. 342 p. 349 p. 349 p. 353 p. 353 p. 353 Pinout Diagram p. 324 p. 328 p. 328 p. 324 p. 311 p. 330 p. 342 p. 342 p. 352 p. 351 p. 357 p. 357 p. 357

CL2 Tray 2/3 Electromagnetic (Turn) Fig. 7, p. 366 / 7 Clutch SL1 Tray 2/3 Feed Solenoid Fig. 7, p. 366 / 8 Fig. 8, p. 366/ 9 Fig. 8, p. 366/ 10 Fig. 9, p. 367/ 11 Fig. 9, p. 367/ 12 Fig. 9, p. 367/ 13

Duplex

Offset motor Duplex motor

HCF

Elevator motor Feed motor Transport motor

Chapter 5. Locations

364

2 3 6 5 4
hc2m222F

Figure 6. Clutches, Solenoids, Motors, and Fans: Printer

Chapter 5. Locations 365

HC2M122F

Figure 7. Clutches, Solenoids, Motors, and Fans: Trays

10

HC2M118F

Figure 8. Clutches, Solenoids, Motors, and Fans: Duplex

Chapter 5. Locations 366

12 11 13

hc2m130F

Figure 9. Clutches, Solenoids, Motors, and Fans: HCF

Connectors
Table 61. Connectors, Printer
Connector P/J 11 12 13 14 15 16 Figure / Grid Fig. 11, p. 375 / C4 Fig. 11, p. 375 / B3 Fig. 11, p. 375/ B4 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / B3 From... MCU PWB... LVPS Assembly MCU PWB... ROS Assembly MCU PWB... High Harness Assembly (Registration Clutch, Registration Sensor, No Paper Sensor, and Feed Solenoid) MCU PWB... High Harness Assembly (Full Stuck Sensor, Temperature Sensor, and Exit Sensor) MCU PWB... HVPS Assembly MCU PWB... Main Motor To... Wiring Diagram p. 311 p. 315 p. 322 p. 313 p. 319 p. 329 Pinout Diagram p. 311 p. 317 p. 324 p. 314 p. 321 p. 330 Chapter 5. Locations 367

Table 61. Connectors, Printer (continued)


Connector P/J 17 18 19 20 21 22 23 31 112 113 114 121 122 123 124 126 127 Figure / Grid Fig. 11, p. 375 / C2 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / C4 Fig. 11, p. 375 / C4 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / A2 Fig. 11, p. 375 / A1 Fig. 11, p. 375 / A2 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / C3 Fig. 10, p. 373 / B3 Fig. 11, p. 375 / C2 Fig. 11, p. 375 / C3 Fig. 11, p. 375 / C3 From... MCU PWB... CRU Sensor Assembly MCU PWB... Duplex Interface PWB MCU PWB... Fuser Cover Switch (if no Duplex Interface PWB) p. 332 p. 332 p. 310 p. 328 p. 311 p. 331 p. 310 p. 338 p. 317 p. 317 p. 317 p. 311 p. 311 p. 311 p. 311 p. 338 p. 311 To... Wiring Diagram p. 315 Pinout Diagram p. 317

MCU PWB... diagnostic tool console panel (open connector) p. 310 MCU PWB... Feeder PWB MCU PWB... Interlock Switch MCU PWB... Toner Sensor Open connector for producing test print output (two pins) MCU PWB... ESS PWB ROS Assembly (LD Assembly)... MCU PWB ROS Assembly (SOS PWB)... MCU PWB ROS Assembly (Scanner Assembly)... MCU PWB LVPS Assembly... LMCU PWB LVPS Assembly... Fan LVPS Assembly... Interlock Switch LVPS Assembly... High Harness Assembly Heater Rod LVPS Assembly... ESS Open connector (plug) on LVPS Assembly board p. 325 p. 311 p. 331 p. 310 p. 337 p. 315 p. 315 p. 315 p. 311 p. 311 p. 311 p. 311 p. 337 p. 311

Chapter 5. Locations

368

Table 61. Connectors, Printer (continued)


Connector P/J 131 132 134 135 137 142 143 144 145 151 171 180 182 183 184 186 Figure / Grid Fig. 11, p. 375 / C1 Fig. 10, p. 373 / C3 Fig. 10, p. 373 / C3 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / A2 Fig. 10, p. 373 / A3 Fig. 10, p. 373 / A3 Fig. 10, p. 373 / A3 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / A1 Fig. 11, p. 375 / A1 Fig. 11, p. 375 / C4, Fig. 13, p. 377 / B2 Fig. 13, p. 377 / B2 Fig. 13, p. 377 / A2 Fig. 13, p. 377 / A2 From... To... Wiring Diagram p. 322 p. 322 p. 322 p. 322 p. 322 p. 313 p. 313 p. 313 p. 313 p. 319 p. 315 p. 332 p. 349 p. 349 p. 349 p. 349 Pinout Diagram p. 324 p. 324 p. 324 p. 324 p. 324 p. 314 p. 314 p. 314 p. 314 p. 321 p. 317 p. 333 p. 351 p. 351 p. 349 p. 352

Registration Clutch Assembly... High Harness Assembly (MCU PWB) Registration Sensor... High Harness Assembly (MCU PWB) MSI No Paper Sensor... MCU PWB Feed Solenoid... High Harness Assembly (MCU PWB) MSI Bracket Assembly (MSI N/P Harness)... High Harness Assembly (MCU PWB) Fuser Assembly (Heater Assembly)... Transport Chute Assembly (High Harness Assembly (MCU PWB) Temperature Sensor Assembly... Fuser Harness (MCU PWB) Exit Sensor... MCU PWB Full Stuck Sensor... MCU PWB HVPS Assembly... MCU PWB CRU Sensor Assembly internals... MCU PWB Duplex Interface PWB... Fuser Cover Switch Duplex Interface PWB... Duplex Unit (Duplex Cable) Duplex Cable... Duplex PWB Duplex Sensor Harness... Duplex PWB Offset Motor... Duplex PWB

Chapter 5. Locations

369

Table 61. Connectors, Printer (continued)


Connector P/J 187 190 192 193 195 196 197 198 201 202 203 204 205 206 Figure / Grid Fig. 13, p. 377 / A2 Fig. 11, p. 375 / C4 Fig. 13, p. 377 / A3 Fig. 13, p. 377 / A2 Fig. 13, p. 377 / A4 Fig. 13, p. 377 / A2 Fig. 13, p. 377 / A3 Fig. 13, p. 377 / B2 Fig. 11, p. 375 / B3, Fig. 12, p. 376 / A3 Fig. 11, p. 375 / B3, Fig. 12, p. 376 / A3 Fig. 11, p. 375 / B3, Fig. 12, p. 376 / B3 Fig. 11, p. 375 / C2, Fig. 12, p. 376 / B2 Fig. 11, p. 375 / C2, Fig. 12, p. 376 / B3 Fig. 11, p. 375 / C1, Fig. 12, p. 376 / B2, From... To... Wiring Diagram p. 349 p. 332 p. 349 p. 349 p. 349 p. 349 p. 349 p. 349 p. 342 p. 342 p. 342 p. 342 p. 342 p. 342 Pinout Diagram p. 349 p. 333 p. 349 p. 349 p. 349 p. 352 p. 349 p. 349 p. 345 p. 346 p. 342 p. 342 p. 342 p. 342

Duplex Motor Harness... Duplex PWB Fuser Cover Switch... Duplex Interface PWB Duplex Sensor Harness... Duplex Stack Sensor Duplex Sensor Harness... Duplex Cover Switch 1 Duplex Motor Harness... Duplex Pass Sensor Offset Motor Duplex Motor Harness... Duplex Motor Duplex Sensor Harness... Duplex Cover Switch 1 Feeder PWB... MCU PWB Feeder PWB... Tray Lower1 Harness Feeder PWB... Feeder Harness (Turn Clutch, No Paper Sensor, and Feed Solenoid) Feed Solenoid... MCU PWB Cassette No Paper Sensor... MCU PWB Electromagnetic Clutch... MCU PWB

Chapter 5. Locations

370

Table 61. Connectors, Printer (continued)


Connector P/J 207 221 222 421 904 906 922 935 937 942 943 CR DB DTS M1 Figure / Grid Fig. 10, p. 373 / C1, Fig. 12, p. 376 / A3, B3 Fig. 10, p. 373 / C3 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / A1 Fig. 11, p. 375 / C2, Fig. 12, p. 376 / B2 Fig. 12, p. 376 / B2 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / C2 Fig. 10, p. 373 / A2 Fig. 10, p. 373 / A3 Fig. 11, p. 375 / A3 Fig. 11, p. 375 / A2 Fig. 11, p. 375 / A3 Fig. 14, p. 378 / C1 From... To... Wiring Diagram p. 342 p. 331 p. 331 p. 334 p. 342 p. 342 p. 331 p. 322 p. 322 p. 313 p. 313 Pinout Diagram p. 342 p. 331 p. 331 p. 336 p. 342 p. 342 p. 331 p. 324 p. 324 p. 314 p. 314 p. 321 p. 321 p. 321 p. 357

Tray Lower1 Harness... options Feeder Assembly (Plugs) Toner Sensor... MCU PWB MSI Bracket Assembly (Toner Sensor Harness)... Toner Relay Harness (MCU PWB) Console Assembly... Controller Feed Solenoid... MCU PWB MCU PWB ... Electromagnetic Clutch Toner Sensor... MCU PWB Feed Solenoid... MCU PWB MSI No Paper Sensor... MCU PWB Fuser Harness... Heater Assembly Fuser Harness internal connector

HVPS Assembly... CRU Guide Assembly Left (Power supply p. 319 for BCR) HVPS Assembly... CRU Guide Assembly Left (Power supply p. 319 for magnet roll) HVPS Assembly... High Harness Assembly (Power supply for Detack Saw) Harness... Lift Up Motor p. 319 p. 353

Chapter 5. Locations

371

Table 61. Connectors, Printer (continued)


Connector P/J M2 P1 P2 S1 S2 S3 S6 S7 S8 S9 S10 S11 S12 TR XS1 XS2 XS3 XS4 Figure / Grid Fig. 14, p. 378 / C4 Fig. 14, p. 378 / A3 Fig. 14, p. 378 / A3 Fig. 14, p. 378 / C1 Fig. 14, p. 378 / C1 Fig. 14, p. 378 / C1 Fig. 14, p. 378 / A4 Fig. 14, p. 378 / A4 Fig. 14, p. 378 / C4 Fig. 14, p. 378 / C4 Fig. 14, p. 378 / A3 Fig. 14, p. 378 / A3 Fig. 14, p. 378 / B3 Fig. 11, p. 375 / B3 Fig. 14, p. 378 / A2 Fig. 14, p. 378 / A2 Fig. 14, p. 378 / A2 Fig. 14, p. 378 / A1 From... Flat Harness... Transport Motor Flat Harness... Kit Feed Roller Flat Harness... Kit Feed Roller Harness... Near Empty Sensor Harness... Lower Position Sensor Harness... Size Sensor Flat Harness... Tray Set Sensor 1 Flat Harness... Tray Set Sensor 2 Flat Harness... Sensor Flat Harness... Left Hand Cover Open Switch Flat Harness... Paper Level Sensor Flat Harness... Upper Limit Sensor Flat Harness... Right Hand Cover Open Switch HVPS Assembly... High Harness Assembly (Power supply for BTR) LVPS... Harness LVPS... Flat Harness LVPS... Kit Connector Base Engine... Kit Connector To... Wiring Diagram p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 319 p. 353 p. 353 p. 353 p. 353 Pinout Diagram p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 357 p. 321 p. 357 p. 357 p. 353 p. 353

Chapter 5. Locations

372

J142, J942

J143, J943 J145 J144

J421

J207 J135, J935 J222, J922 J137, J937 J221


1 2 3

J132

J134
HC2M111F

Figure 10. Connectors, Printer

Chapter 5. Locations 373

Chapter 5. Locations 374

J180 J113
A

J171

J114 J112 DB DTS


A

CR

J151 TR J12
B

J31

J23 J15 J19


B

J123 J202 J201 J121 J203

J17 J14 J18 J16 J21 J11

J22 J13

J20

J127 J131
C

J126 J190 J182


C

J206 J204,J904 J205 J124

J122

HC2M112F

Figure 11. Connectors, Printer

Chapter 5. Locations 375

J201 J202

J207

P207
B B

J206, J906 J204, J904 J205

J203

hc2m126F

Figure 12. Connectors, Trays

Chapter 5. Locations 376

J192 J193 J186


A

J197

J196

J184 J187 J195 J183

P182

J198

hc2m117F

Figure 13. Connectors, Duplex

Chapter 5. Locations 377

P1 XS1 XS4 XS2 S10 XS3 S12 S11

P2

S6

S7

M2 S3 S1 M1 S2 S9
C

S8

hc2m128F

Figure 14. Connectors, HCF

Chapter 5. Locations 378

Chapter 5. Locations 379

Printed Wiring Boards (PWBs)


Table 62. Printed Wiring Boards (PWBs)
Unit Printer PWB Control panel (console) Controller PWB HVPS Feeder PWB LVPS MCU PWB Duplex Interface PWB Duplex Feeder HCF Duplex PWB Tray 2/3 Feeder PWB LVPS Figure / Reference Fig. 15, p. 381 / 1 Fig. 15, p. 381 / 2 Fig. 15, p. 381 / 3 Fig. 15, p. 381 / 4 Fig. 15, p. 381 / 5 Fig. 15, p. 381 / 7 Fig. 15, p. 381/ 6 Fig. 17, p. 382 / 9 Fig. 16, p. 381 / 8 Parts Catalog Asm. Index 118, p. 548 136, p. 578 1211, p. 575 31, p. 553 124, p. 575 128/9, p. 575 126, p. 575 3010, p. 652 2011, p. 697 Wiring Diagram (Grid) p. 334 p. 337 p. 319 p. 342 p. 311 p. 310 p. 349 p. 349 p. 342 p. 353 Pinout Diagram (Grid) p. 336 p. 338 p. 321 p. 342 p. 311 p. 310 p. 349 p. 349 p. 342 p. 357 Removal p. 418 p. 537 p. 532 p. 420 p. 521 p. 526 or p. 529 p. 524 p. 627 p. 674 p. 674

Fig. 18, p. 383 / 10 4225, p. 778

Chapter 5. Locations 380

1 3

2 4

HC2M116F

7 6 5

Figure 15. Printed Wiring Boards (PWBs): Printer

HC2M125F

Figure 16. Printed Wiring Boards (PWBs): Trays

Chapter 5. Locations 381

HC2M121F

Figure 17. Printed Wiring Boards (PWBs): Duplex

Chapter 5. Locations 382

10

hc2m129F

Figure 18. Printed Wiring Boards (PWBs): HCF

Chapter 5. Locations 383

Sensors
Table 63. Sensors
Unit CRU sensor Full stack sensor Exit sensor Printer Temperature sensor Registration sensor Auxiliary tray no-paper sensor Toner sensor Cassette no-paper sensor Duplex Feeder Duplex stack sensor Duplex pass sensor Sensor Figure / Reference Fig. 19, p. 387 / 1 Fig. 19, p. 387/ 2 Fig. 19, p. 387/ 3 Fig. 19, p. 387/ 4 Fig. 19, p. 387/ 5 Fig. 19, p. 387/ 6 Fig. 19, p. 387/ 7 Fig. 19, p. 387/ 10 Fig. 21, p. 388 / 14 Fig. 21, p. 388/ 13 Parts Catalog Asm. Index 1115, p. 572 87, p. 564 825, p. 564 99, p. 567 76, p. 562 59, p. 557 513, p. 557 311, p. 553 3017, p. 652 3013, p. 652 2021, p. 697 Wiring Diagram (Grid) p. 315 p. 313 p. 313 p. 313 p. 322 p. 322 p. 331 p. 342 p. 349 p. 349 p. 342 Pinout Diagram (Grid) p. 317 p. 314 p. 314 p. 314 p. 324 p. 324 p. 331 p. 342 p. 349 p. 349 p. 342 Removal p. 503 p. 487 p. 487 p. 487 p. 484 p. 460 p. 462 p. 430 p. 635 p. 633 p. 683

Tray 2/3 cassette no-paper sensor Fig. 20, p. 388 / 12

Chapter 5. Locations 384

Table 63. Sensors (continued)


Unit Sensor Near empty sensor Size sensor Lower position sensor Sensor HCF Upper limit sensor No paper sensor Tray set sensor 1 Tray set sensor 2 Paper level sensor Figure / Reference Fig. 22, p. 389 / 17 Fig. 22, p. 389 / 18 Fig. 22, p. 389 / 19 Fig. 22, p. 389 / 27 Fig. 22, p. 389 / 23 Fig. 22, p. 389 / 25 Fig. 22, p. 389 / 21 Fig. 22, p. 389 / 20 Fig. 22, p. 389 / 22 Parts Catalog Asm. Index 4111, p. 776 4115, p. 776 4112, p. 776 4210, p. 778 4211, p. 778 4228, p. 778 4218, p. 778 4219, p. 778 4212, p. 778 Wiring Diagram (Grid) p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 Pinout Diagram (Grid) p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 p. 353 Removal p. 731 p. 735 p. 733 p. 745 p. 750 p. 747 p. 756 p. 756 p. 752

Chapter 5. Locations 385

Switches
Table 64. Switches
Unit Switch Interlock switch Fuser cover switch Duplex cover switch 1 Duplex cover switch 2 Paper size switch (on feeder PWB) Right hand cover open switch Left hand cover open switch Figure / Reference Fig. 19, p. 387 / 8 Fig. 19, p. 387/ 9 Fig. 21, p. 388 / 15 Fig. 21, p. 388/ 16 Fig. 20, p. 388 / 11 Fig. 22, p. 389 / 24 Fig. 22, p. 389 / 26 Parts Catalog Asm. Index 121, p. 575 122, p. 575 3011, p. 652 3012, p. 652 2011, p. 697 429, p. 778 4220, p. 778 Wiring Diagram (Grid) p. 311 p. 332 p. 349 p. 349 p. 342 p. 353 p. 353 Pinout Diagram (Grid) p. 311 p. 332 p. 349 p. 349 p. 342 p. 353 p. 353 Removal p. 513 p. 516 p. 629 p. 631 p. 674 p. 743 p. 758

Printer

Duplex Trays HCF

Chapter 5. Locations 386

2 3 4

5 7 6

hc2m223F

10

Figure 19. Sensors and Switches: Printer


Chapter 5. Locations 387

11

hc2m224F

12

Figure 20. Sensors and Switches: Trays

13 14

15

16
hc2m225F

Figure 21. Sensors and Switches: Duplex

Chapter 5. Locations 388

22 23 24

21

20

hc2m127F

17

18

19

25

27 26

Figure 22. Sensors and Switches: HCF

Chapter 5. Locations 389

Mechanical and Miscellaneous


Table 65. Mechanical and Miscellaneous Items
Unit Laser Unit (ROS) Fuser Assembly BTR Roll EP Cartridge Pick Up Roller Metal Registration Roller Printer Rubber Registration Roller Drum (part of EP Cartridge) Heat Roller (part of Fuser Assembly) Offset/Exit Roller Pressure Roll (part of Fuser Assembly) BTR Assembly Rear Roll Assembly Turn Roll Assembly Item Figure / Reference Fig. 24, p. 393 / 28 Fig. 24, p. 393 / 29 Fig. 24, p. 393 / 30 Fig. 24, p. 393 / 31 Fig. 23, p. 392 / 1 Fig. 23, p. 392 / 2 Fig. 23, p. 392 / 3 Fig. 23, p. 392 / 4 Fig. 23, p. 392 / 5 Fig. 23, p. 392 / 6 Fig. 23, p. 392 / 12 Fig. 23, p. 392 / 13 Fig. 23, p. 392 / 16 Fig. 23, p. 392 / 17 Parts Catalog Asm. Index 1120, p. 572 8, p. 564 61, p. 559 1140, p. 572 68, p. 559 710, p. 562 711, p. 562 1140, p. 572 910, p. 567 319, p. 655 915, p. 567 61, p. 559 411, p. 555 410, p. 555

Chapter 5. Locations

390

Table 65. Mechanical and Miscellaneous Items (continued)


Unit Exit Pinch Roller Offset Pinch Roller Offset Roller Duplex Duplex Upper Roller Duplex Upper Pinch Roller Duplex Lower Roller Duplex Lower Pinch Roller Tray 1 Pinch Roller Tray 1 Turn Roller Assembly Trays Tray 1 Feed Roller Tray 2 Pinch Roller Tray 2 Turn Roller Assembly Tray 2 Feed Roller Pinch roll HCF Transport roll Pinch roll Feed roll Item Figure / Reference Fig. 23, p. 392 / 7 Fig. 23, p. 392 / 8 Fig. 23, p. 392 / 9 Fig. 23, p. 392 / 10 Fig. 23, p. 392 / 11 Fig. 23, p. 392 / 14 Fig. 23, p. 392 / 15 Fig. 23, p. 392 / 18 Fig. 23, p. 392 / 19 Fig. 23, p. 392 / 20 Fig. 23, p. 392 / 21 Fig. 23, p. 392 / 22 Fig. 23, p. 392 / 23 Fig. 23, p. 392 / 24 Fig. 23, p. 392 / 25 Fig. 23, p. 392 / 26 Fig. 23, p. 392 / 27 Parts Catalog Asm. Index 305, p. 652 317, p. 652 318, p. 655 3111, p. 655 305, p. 652 3112, p. 655 306, p. 652 411, p. 555 410, p. 555 41, p. 555 201, p. 700 2120, p. 700 2111, p. 700 425, p. 778 427, p. 778 425, p. 778 4214, p. 778

Chapter 5. Locations

391

7 6 5 4 3

8 9 10 11 12

13 14

1 15
FRONT

16 17 18 19 20 21 22 23

24 25 26 27
hc2m785F

Figure 23. Mechanical


Chapter 5. Locations 392

28

29

30 31
hc2m226F

Figure 24. Miscellaneous

Chapter 5. Locations 393

Chapter 6. Removal Procedures, Adjustments


Fuser Cover Assembly. . Removal . . . . . . . . Replacement. . . . . . Left Top Cover . . . . . . Removal . . . . . . . . Replacement. . . . . . Right Top Cover . . . . . Removal . . . . . . . . Replacement. . . . . . Left Side Cover Assembly Removal . . . . . . . . Replacement. . . . . . Left Lower Cover . . . . Removal . . . . . . . . Replacement. . . . . . Right Cover Assembly . . Removal . . . . . . . . Replacement. . . . . . Front Side Cover . . . . Removal . . . . . . . . Replacement. . . . . . Exit Cover . . . . . . . . Removal . . . . . . . . Replacement. . . . . . Pop Up Cover Assembly. Removal . . . . . . . . Replacement. . . . . .
Copyright IBM Corp. 1998

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.400 .401 .401 .402 .402 .403 .404 .404 .405 .406 .406 .407 .408 .408 .409 .410 .410 .411 .412 .413 .413 .414 .414 .415 .416 .416 .417 394

Console Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Feeder PWB . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Turn In Chute . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Turn Chute Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette Guide Assembly Left. . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette No Paper Sensor . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette Guide Assembly Right . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette No Paper Actuator . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Feed Roll . . . . . . . . . . . . . . . You may follow either procedure A or Procedure A Removal . . . . . . . . Replacement. . . . . . . . . . . . . Procedure B Removal . . . . . . . . Replacement. . . . . . . . . . . . .

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.418 .419 .419 .420 .420 .421 .422 .423 .423 .424 .425 .425 .426 .426 .428 .430 .430 .431 .433 .433 .435 .436 .436 .437 .438 .438 .439 .439 .439 .440

Chapter 6. Removal Procedures, Adjustments 395

Feed Shaft Assembly . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Feed Solenoid . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Electromagnetic Clutch . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Turn Roll Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Rear Roll Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Front Tray Assembly and Front in Tray . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Auxiliary Tray Bracket Assembly . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Auxiliary Tray No Paper Sensor/Actuator Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Toner Sensor Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Front Bottom Tray . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . .

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.442 .442 .444 .446 .446 .448 .449 .449 .450 .451 .451 .452 .453 .453 .454 .455 .455 .456 .457 .457 .458 .460 .460 .461 .462 .462 .463 .464 .464 .465

Chapter 6. Removal Procedures, Adjustments 396

BTR Assembly . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Chute Assembly. . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Pick Up Roll . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Pick Up Solenoid . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Retard Pad Assembly . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Registration Sensor/Actuator . Removal . . . . . . . . . . . Replacement. . . . . . . . . Fuser Assembly . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Main Motor. . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Handling Gear Assembly Removal . . . . . . . . . . . Replacement. . . . . . . . . Registration Clutch Assembly . Removal . . . . . . . . . . . Replacement. . . . . . . . .

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.466 .467 .467 .468 .468 .471 .474 .474 .475 .477 .477 .478 .480 .481 .482 .484 .484 .486 .487 .488 .488 .489 .490 .490 .492 .493 .494 .495 .495 .496

Chapter 6. Removal Procedures, Adjustments 397

Main Gear Assembly. . . . Removal . . . . . . . . . Replacement. . . . . . . Pop Up Unit . . . . . . . . Removal . . . . . . . . . Replacement. . . . . . . CRU Sensor Assembly . . Removal . . . . . . . . . Replacement. . . . . . . CRU Guide Assembly Left . Removal . . . . . . . . . Replacement. . . . . . . CRU Guide Assembly Right Removal . . . . . . . . . Replacement. . . . . . . Interlock Switch . . . . . . Removal . . . . . . . . . Replacement. . . . . . . Fuser Cover Switch . . . . Removal . . . . . . . . . Replacement. . . . . . . Fan . . . . . . . . . . . . Removal . . . . . . . . . Replacement. . . . . . . LVPS Assembly . . . . . . Removal . . . . . . . . . Replacement. . . . . . . Duplex Interface PWB . . . Removal . . . . . . . . . Replacement. . . . . . .

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.497 .497 .499 .500 .501 .502 .503 .504 .505 .506 .507 .508 .510 .510 .511 .513 .513 .515 .516 .516 .517 .518 .519 .519 .521 .522 .523 .524 .525 .525

Chapter 6. Removal Procedures, Adjustments 398

MCU PWB without MCU Holder . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . MCU PWB with MCU Holder . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . HVPS . . . . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller Assembly . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller PWB . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller PWB SIMM . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Network Interface Card . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

.526 .527 .527 .529 .530 .531 .532 .532 .533 .535 .535 .536 .537 .537 .538 .539 .539 .540 .541 .541 .542

Chapter 6. Removal Procedures, Adjustments 399

Fuser Cover Assembly


Asm-Index: 1-1, page 548.
4 6
FRONT

hc2m957f

Figure 25. Fuser Cover Assembly Removal

Chapter 6. Removal Procedures, Adjustments 400

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove duplex unit (See page 615), if supplied. 3. Open the fuser cap cover (1) (Asm-Index: 1-3, page 548). 4. Lift up the fuser cap cover and remove from the fuser cover (2) (Asm-Index: 1-2, page 548). 5. Open the fuser cover and hold the cover midway (approximately 30 degrees). 6. Use you right hand to hold the left end of the fuser cover, and press its center from the inside. Use your left hand to unhook the right side hinge pin (5) from the hinge hole on the rear tie plate (6) (Asm-Index: 10-5, page 570). 7. Release the left side hinge pin (3) of the fuser cover from the hinge hole on the rear tie plate (6).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 401

Left Top Cover


Asm-Index: 1-4, page 548.

1 2
J131

hc2m958F

Figure 26. Left Top Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).
Chapter 6. Removal Procedures, Adjustments 402

3. Open the front tray assembly (Asm-Index: 5-1, page 557). 4. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572). 5. Remove the two screws (2) securing the left top cover to the printer frame. 6. Lift up the back of the left top cover. 7. Release the hook (3) from the front side cover (Asm-Index: 1-11, page 548) and remove the left top cover from the printer body. Attention: Support the left top cover to prevent damage to the console earth wire and the console harness. 8. Turn the left top cover to the left. 9. Disconnect CN1 of the console harness (Asm-Index: 13-8, page 578) at the back of the console assembly (Asm-Index: 1-18, page 548).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 403

Right Top Cover


Asm-Index: 1-5, page 548.

2 2

hc2m413f

Figure 27. Right Top Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 404

3. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572) 4. Remove the two screws (2) securing the right top cover. 5. Lift the cover away from the printer frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 405

Left Side Cover Assembly


Asm-Index: 1-6, page 548.

FRONT

4 3 5 8 7 1 8

6 7 1 2 6
hc2m972f

Figure 28. Left Side Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Loosen the two knurled screws (1) securing the left cover assembly (2).
Chapter 6. Removal Procedures, Adjustments 406

3. Slide the cover backwards to remove its front edge from the front side cover (3) (Asm-Index: 1-11, page 548), and remove the cover from the printer frame.

Replacement
1. Insert the top edge of the cover (4) into the top slot (5). 2. Line the three hooks (6) up with the three openings (7) in the printer frame. 3. Slide the cover toward the front of the printer until the front tabs (8) t into the grooves on the front side cover (3). Attention: Ensure that the top edge of the cover ts inside the lower edge of the left top cover. 4. Secure the left cover assembly using two knurled screws.

Chapter 6. Removal Procedures, Adjustments 407

Left Lower Cover


Asm-Index: 1-9, page 548.

2 1

hc2m415f

Figure 29. Left Lower Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left cover assembly (See page 406). 3. Remove the two screws (1) securing the left lower cover (2). 4. Remove the cover from the printer frame.

Chapter 6. Removal Procedures, Adjustments 408

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 409

Right Cover Assembly


Asm-Index: 1-10, page 548.

1 3
hc2m416f

Figure 30. Right Cover Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 410

3. Remove the right top cover (See page 404). 4. Remove the two screws (1) securing the bottom of the right cover assembly (2). 5. Remove the three screws (3) securing the top and back of the cover. 6. Remove the cover.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 411

Front Side Cover


Asm-Index: 1-11, page 548.

1 1

hc2m417f

Figure 31. Front Side Cover Removal

Chapter 6. Removal Procedures, Adjustments 412

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Push down on the two hooks (1) at the upper end of the front side cover and move the top of the cover away from the printer frame. 6. Lift up the cover slightly to clear the two hooks (2) at the bottom of the cover and remove the cover from the printer frame.

Replacement
1. Hold the front side cover slightly tilting the upper side toward the front, and insert the hooks (2) on the bottom end of the cover into the opening in the printer frame. 2. Push down on the two hooks (1) at the upper end of the cover and insert them into the openings of the printer frame. 3. Replace the left cover assembly (See page 406). 4. Replace the left top cover (See page 402). 5. Close the fuser cover assembly (Asm-Index: 1-1, page 548).

Chapter 6. Removal Procedures, Adjustments 413

Exit Cover
Asm-Index: 1-12, page 548.
1 1

hc2m418f

Figure 32. Exit Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). Note: Removing the fuser allows cables/wires to be re-routed on the cover wire retainer during replacement. 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Close the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572).
Chapter 6. Removal Procedures, Adjustments 414

6. Remove the two screws (1) securing the exit cover (2). 7. Tilt the exit cover toward the front so that the full stack actuator (3) (Asm-Index: 8-8, page 564) does not touch the cover. 8. Lift the cover and remove it from the printer frame.

Replacement
1. 2. 3. 4. 5. Lift the full stack actuator and hold it out of the way so that it will not touch the exit cover during step 2. Place the cover onto the printer frame. Secure the cover using two screws (silver, collared, 10mm). Open the Pop up/ROS assembly. Replace the right top cover (See page 404).

6. Replace the left top cover (See page 402). 7. Replace the fuser cover assembly (See page 402).

Chapter 6. Removal Procedures, Adjustments 415

Pop Up Cover Assembly


Asm-Index: 1-13, page 548.
3

1 3

hc2m419f

Figure 33. Pop Up Cover Assembly Removal

Removal
See Figure 33. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 416

3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the exit cover (See page 414). 6. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572). 7. Remove the two screws (2) securing the pop up cover assembly. 8. Close the Pop up/ROS assembly. 9. Slide the pop up cover assembly slightly toward the front of the printer to disengage the hooks (3) at the front and back of the cover. 10. Lift the cover assembly and remove the cover from the pop up frame (Asm-Index: 11-1, page 572).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 417

Console Assembly
Asm-Index: 1-18, page 548.
CN1

JCN1

J131

hc2m41af

Figure 34. Console Assembly Removal

Chapter 6. Removal Procedures, Adjustments 418

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548). 3. Remove the left top cover (See page 402) and the console assembly (2)(Asm-Index: 1-18, page 548). 4. Turn the left top cover (1) upside down. 5. Release the tab at the bottom of the console assembly.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 419

Feeder PWB
Asm-Index: 3-1, page 553.

2
J201 J202 FRONT

3
J203

hc2m973f

Figure 35. Feeder PWB Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Remove the left top cover (See page 402). 4. Remove the left side cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 420

5. Remove the left lower cover (See page 408). 6. Remove the front side cover (See page 412). 7. Remove the controller (See page 535). 8. Remove the four screws (3) securing the feeder PWB (4). Note: To loosen the bottom left screw, insert the screwdriver through the opening in the printer frame. 9. Remove the tray lower 1 harness (1) (Asm-Index: 3-2, page 553) from the harness clamp (2). 10. Remove the feeder PWB from the printer frame. 11. Disconnect J201 of the tray harness (Asm-Index: 12-17, page 575), J202 of the tray lower 1 harness and J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 421

Turn In Chute
Asm-Index: 3-4, page 553.
FRONT

3 1

hc2m974F

Figure 36. Turn In Chute Removal

Chapter 6. Removal Procedures, Adjustments 422

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Hold open the turn chute assembly (Asm-Index: 3-5, page 553). 4. Flex the left side arm (1) of the turn in chute and remove its hinge hole from the pin (2) on the cassette guide assembly left (Asm-Index: 3-6, page 553). 5. Remove the turn in chute (3) from the cassette guide (4).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 423

Turn Chute Assembly


Asm-Index: 3-5, page 553.

2 1 2

hc2m433F

Figure 37. Turn Chute Assembly Removal

Chapter 6. Removal Procedures, Adjustments 424

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the turn in chute (See page 422). 3. 4. 5. 6. 7. 8. Hold the turn chute assembly (1) half open. Unhook the stoppers from the cassette guide left and right. Hold the chute assembly open and slide it to the left. Lift the rear of the printer and pull down the right side of the chute. Slide the chute to the right and remove it from the printer. Lower the printer.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 425

Cassette Guide Assembly Left


Asm-Index: 3-6, page 553.

4 5

J203

1 3
J206 J204

3
hc2m434f

Figure 38. Cassette Guide Assembly Left Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 426

3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the turn in chute (See page 422). 7. Remove the turn chute assembly (See page 424). 8. Remove the controller assembly (See page 535). 9. Remove the LVPS assembly (See page 521). 10. Disconnect v J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB (Asm-Index: 3-1, page 553), v J204 from the feed solenoid (Asm-Index: 4-8, page 555), and v J206 of the feeder harness from the electromagnetic clutch (Asm-Index: 4-9, page 555). 11. Release the electromagnetic clutch side of the feeder harness from the clamp. 12. Remove the four screws (1) securing the cassette guide assembly left from outside of the frame.

13. Using a at blade screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in, one by one, to release them from the printer frame. 14. Tilt the cassette guide (4), pulling its bottom edge from the inside of the printer frame (5). 15. Ensure that the three upper hooks of the cassette guide are released from the printer frame.

Chapter 6. Removal Procedures, Adjustments 427

16. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator (Asm-Index: 3-16, page 553). 17. Push all harnesses on the cassette guide to free them from the printer frame. 18. Remove the cassette guide from the printer frame.

Replacement
1. Hold the cassette guide assembly left with the bottom to the right and the top to the left so that it will not interfere with the cassette no paper actuator. 2. Insert the cassette guide into the paper cassette well. 3. Insert all connectors on the cassette guide through their openings in the printer frame. 4. Place the upper three hooks of the cassette guide in their holes in the printer frame. 5. Pull the harnesses to keep them from being pinched between the cassette guide and the printer frame. Note: Adjust the position of cassette guide by sliding it to the front or rear so that the positioning pins on the cassette guide enter into the openings in the printer frame. Press on the bottom of the cassette guide to tilt it up until the upper and lower hooks lock into position. Secure the cassette guide from the outside of the printer frame using the four screws (1). Reconnect: v J203 to the feeder PWB, v J204 to the feed solenoid, and v J206 to the electromagnetic clutch. Insert the electromagnetic clutch harness into the harness clamp. Replace the LVPS assembly (See page 521).

6. 7. 8.

9. 10.

11. Replace the controller assembly (See page 535). 12. Replace the turn chute assembly (See page 424). 13. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 428

14. Replace the front side cover (See page 412). 15. Replace the left cover assembly (See page 406). 16. Replace the left top cover (See page 402). 17. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 429

Cassette No Paper Sensor


Asm-Index: 3-11, page 553.

J205

hc2m435f

Figure 39. Cassette No Paper Sensor Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Open the fuser cover assembly (See page 400). 4. Remove the left top cover (See page 402).

Chapter 6. Removal Procedures, Adjustments 430

5. Remove the left cover assembly (See page 406). 6. Remove the front side cover (See page 412). 7. Remove the controller assembly (See page 535). 8. Remove the turn in chute (See page 422). 9. Swing the arm of the cassette no paper actuator (1) (Asm-Index: 3-16, page 553) to the rear direction so that the actuator is away from the cassette no paper sensor (2). 10. Open the turn chute assembly (Asm-Index: 3-5, page 553). 11. Using a small screwdriver, release the hooks (3) of the cassette no paper sensor from the cassette guide assembly left (Asm-Index: 11-30, page 572). Attention: Do not move the cassette no paper sensor away. It is connected with the feeder harness. 12. Disconnect J205 from the sensor. 13. Remove the sensor.

Replacement
1. Swing up the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette no paper sensor. 2. Reconnect J205 to the cassette no paper sensor. 3. Position the sensor in the opening of the cassette guide, and press the sensor into place until it snaps into position. 4. Put the extra length of the harness into the wiring channel of the cassette guide so that the harness does not interfere with the gears. 5. Replace the turn in chute (See page 422) and close the turn chute assembly. 6. Replace the controller assembly (See page 535). 7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 431

8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400). 11. Replace the paper cassette.

Chapter 6. Removal Procedures, Adjustments 432

Cassette Guide Assembly Right


Asm-Index: 3-13, page 553.

3 1 3
hc2m436f

Figure 40. Cassette Guide Assembly Right Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the right top cover (See page 404). 4. Remove the right cover assembly (See page 410).

Chapter 6. Removal Procedures, Adjustments 433

5. Remove the front tray assembly (See page 455). 6. Remove the turn in chute (See page 422). 7. Remove the turn chute assembly (See page 424). 8. Remove the three screws (1) securing the cassette guide assembly right (2). 9. Using a screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in, one by one, to release them from the printer frame (4). 10. Tilt the cassette guide, pulling its bottom edge from the inside of the printer frame. 11. Ensure that three upper hooks of the cassette guide are released from the printer frame. 12. Remove the cassette guide from the printer.

Chapter 6. Removal Procedures, Adjustments 434

Replacement
1. Hold the cassette guide assembly right with the lower side to the left and the upper side to the right. 2. Insert the cassette guide into the paper cassette well. 3. Position the upper three hooks of the cassette guide in their respective holes. Note: Adjust the position of the cassette guide by sliding it to the front or rear so that the positioning pins on the cassette guide enter into the openings in the printer frame. 4. Press the lower side of the cassette guide tilting it up until the upper and lower hooks are in position and the lower hooks snap into place. 5. Secure the cassette guide using three screws (gold, self tapping, 8mm). 6. Replace the turn chute assembly (See page 424). 7. Replace the turn in chute (See page 422). 8. Replace the front tray assembly (See page 455). 9. Replace the right cover assembly (See page 410). 10. Replace the right top cover (See page 404). 11. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 435

Cassette No Paper Actuator


Asm-Index: 3-16, page 553.

hc2m437f

Figure 41. Cassette No Paper Actuator Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the left lower cover (See page 408).
Chapter 6. Removal Procedures, Adjustments 436

6. Remove the front side cover (See page 412). 7. Remove the front tray assembly (See page 455). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the LVPS assembly (See page 521). 12. Remove the cassette guide assembly left (See page 426). 13. Slide the shaft of the cassette no paper actuator (1) to the right (2). 14. Release the left end of the actuator from the hole. 15. Slide the actuator to the left and remove it from the printer frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 437

Feed Roll
Asm-Index: 4-1, page 555.

2 1

hc2m441f

Figure 42. Feeder Roll Removal

You may follow either procedure A or B.


Note: The feed rollers are in the correct position for removal if power is switched off approximately 4 seconds after initiating a print command.

Chapter 6. Removal Procedures, Adjustments 438

Procedure A Removal
1. Install the paper cassette (Asm: 2, page 550) (with paper). 2. Open the turn chute assembly (Asm-Index: 3-5, page 553) and watch the paper path. 3. Run a test print and switch off the main switch when the front end of the paper touches the turn roll assembly (Asm-Index: 4-10, page 555). 4. Remove the paper cassette. 5. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper actuator (Asm-Index: 3-16, page 553) with your rst, second and third ngers. 6. Press on the hook of the feed roll (1) to the front using your thumb to remove it.

Replacement
1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly. Note: Ensure that the cams are located between the left and right pairs of the feed roll. 3. Switch on the main power. 4. Replace the paper cassette.

Procedure B Removal
1. Remove the fuser cover assembly (See page 400). 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 439

6. Remove the turn chute assembly (See page 424). 7. Remove the controller assembly (See page 535). 8. Press down on the armature of the feed solenoid (2) (Asm-Index: 4-8, page 555) to engage the feed gear (3) (Asm-Index: 4-5, page 555) with the feed idler gear (4) (Asm-Index: 4-15, page 555). 9. Rotate the rotor (5) of the main motor (Asm-Index: 10-6, page 570) clockwise until the rubber surface of the feed roll faces to the front. Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls. 10. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper actuator, with your rst, second and third ngers. 11. Press on the hook of the feed roll to the front using your thumb to remove it.

Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly. Note: Ensure that the cams are located between the left and right pairs of the feed roll. 3. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of the feed roll (Asm-Index: 4-1, page 555) up until the feed gear (Asm-Index: 4-5, page 555) is released from the feed idler gear (Asm-Index: 4-15, page 555). 4. Replace the controller assembly (See page 535). 5. Replace the turn chute assembly (See page 424). 6. Replace the turn in chute (See page 422). 7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 440

8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 441

Feed Shaft Assembly


Asm-Index: 4-2, page 555.

1 4 6 7 3

5
hc2m442f

Figure 43. Feeder Shaft Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).

Chapter 6. Removal Procedures, Adjustments 442

4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the four feed rolls (See page 438). 12. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555) and the feed solenoid (3) (Asm-Index: 4-8, page 555). 13. Remove the E-ring (4) that secures the feed gear to the feed shaft assembly (5). 14. Hold down the armature of the feed solenoid and remove the feed gear together with the feed core (Asm-Index: 4-3, page 555) and the feed core spring (Asm-Index: 4-4, page 555). 15. Remove the E-ring (6) that secures the right end the feed shaft assembly and remove the right side feed bearing (7) (Asm-Index: 4-6, page 555). 16. Slide the feed shaft to the left and remove the E-ring (8) that secures its left end. Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls. 17. Position the cassette no paper actuator at the lower position. 18. Slide the feed shaft to the right until its left end clears the printer frame. 19. Pull the feed shaft to the lower left and release its right end from the printer frame, and remove the shaft from the printer.

Chapter 6. Removal Procedures, Adjustments 443

Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Position the cassette no paper actuator in the lower position. 2. Hold the feed shaft assembly with the at side to the left. 3. Hold the feed shaft, left end lowered and insert its right end into the right opening in the printer frame. 4. Slide the feed shaft to the right and insert its left end to the feed bearing. 5. Slide the feed shaft to the left and install an E-ring in the second groove from the left end. You may pull out the right end of the shaft to ease the installation of the E-ring. 6. Pressing the left end of the feed shaft to the right, insert the right side feed bearing into its opening in the printer frame. 7. Reinstall an E-ring to secure the right end of the feed shaft. 8. Rotate the shaft and position the at side up. 9. Holding down the armature of the feed solenoid, install the feed gear together with the feed core and the feed core spring. 10. Secure the feed gear to the feed shaft using an E-ring. 11. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) to the position that the larger holes on the feed shaft can be seen from the back of the printer body. 12. Replace the four feed rolls (See page 438). 13. Reinstall the feed spring between the feed gear and the feed solenoid. 14. Rotate the rotor of the main motor clockwise to place the rubber surface of the feed roll up until the feed gear is released from the feed idler gear (Asm-Index: 4-15, page 555). 15. Replace the controller assembly (See page 535). 16. Replace the turn chute assembly (See page 424). 17. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 444

18. Replace the front side cover (See page 412). 19. Replace the right cover assembly (See page 410). 20. Replace the left cover assembly (See page 406). 21. Replace the right top cover (See page 404). 22. Replace the left top cover (See page 402). 23. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 445

Feed Solenoid
Asm-Index: 4-8, page 555.

1 4

3
J204

hc2m443f

Figure 44. Feed Solenoid Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 446

3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555) and the feed solenoid (3). 8. Disconnect J204 of the feed solenoid (4) from the feeder harness (Asm-Index: 3-12, page 553) on the cassette guide assembly left (Asm-Index: 3-6, page 553). 9. Remove the screw (5) securing the feed solenoid to the cassette guide and remove the solenoid.

Chapter 6. Removal Procedures, Adjustments 447

Replacement
1. Place the feed solenoid in position and secure it using a screw (silver, 6mm). 2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly left. Attention: Route the harness so that it does not touch the gears. 3. Reinstall the feed spring between the feed gear and the feed solenoid. 4. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of the feed roll (Asm-Index: 4-1, page 555) up until the feed gear is released from the feed idler gear (Asm-Index: 4-15, page 555). 5. Press the armature of the feed solenoid and ensure the feed gear is released from the armature. 6. Turn the feed gear clockwise and ensure the armature of the feed solenoid holds the feed gear. 7. Replace the controller assembly (See page 535). 8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402). 11. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 448

Electromagnetic Clutch
Asm-Index: 4-9, page 555.

1 2

J206
hc2m444f

Figure 45. Electromagnetic Clutch Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535).
Chapter 6. Removal Procedures, Adjustments 449

7. Disconnect J206 from the electromagnetic clutch (1). 8. Remove the E-ring (2) securing the clutch. 9. Remove the clutch from the turn roll assembly (Asm-Index: 4-10, page 555).

Replacement
1. Place the electromagnetic clutch on the turn roll assembly and insert the notch on the clutch to the arm over the printer frame. 2. Secure the clutch using an E-ring. 3. Reconnect P/J206 to the clutch. Attention: Route the harness so that it does not touch the gears. 4. Replace the controller assembly (See page 535). 5. Replace the front side cover (See page 412). 6. Replace the left cover assembly (See page 406). 7. Replace the left top cover (See page 402). 8. Remove the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 450

Turn Roll Assembly


Asm-Index: 4-10, page 555.

3
hc2m445f

Figure 46. Turn In Roll Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410).
Chapter 6. Removal Procedures, Adjustments 451

7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the electromagnetic clutch (See page 449). 12. Remove the left side E-ring (1) securing the turn gear (2) (Asm-Index: 4-12, page 555) and remove the gear from the turn roll assembly (3). 13. Remove the bearing from the turn roll assembly. 14. Remove the right side E-ring (5) securing the right side turn bearing (6) and remove the bearing from the turn roll assembly. 15. Slide the turn roll assembly to the left, and remove its right end from the printer frame. 16. Slide the right end of the turn roll assembly backward, and remove its left end from the printer frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 452

Rear Roll Assembly


Asm-Index: 4-11, page 555.

5
hc2m446f

Figure 47. Rear Roll Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410).
Chapter 6. Removal Procedures, Adjustments 453

7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the E-ring (1) securing the right side turn bearing (2) (Asm-Index: 4-13, page 555) and remove the bearing from the printer frame. 12. Remove the E-ring (3) securing the turn gear (4) (Asm-Index: 4-12, page 555) and remove the gear from the rear roll assembly (5). 13. Remove the left side turn bearing (6) from the rear roll assembly. 14. Slide the rear roll assembly to the left, and remove its right end from the printer frame. 15. Slide the right end of the rear roll assembly to the rear, and remove its left end from the printer frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 454

Front Tray Assembly and Front in Tray


Asm-Index: 5-1 and 5-4, page 557.

2 1

hc2m451f

Figure 48. Front Tray Assembly and Front In Tray Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 455

6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the two screws (1) securing the front in tray (2). 9. Open the front tray and pull out the front in tray together with the front tray assembly (3). 10. Flex the arm of the front in tray to release the hinge on the front tray assembly to separate the front in tray and the front tray assembly.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 456

Auxiliary Tray Bracket Assembly


Asm-Index: 5-7, page 557.

2 1 1 3
hc2m452f

4
J222 J137

Figure 49. Auxiliary Tray Bracket Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the front tray assembly (Asm-Index: 5-1, page 557).

Chapter 6. Removal Procedures, Adjustments 457

3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and keep it open during the operation below. 4. Remove the EP cartridge (Asm-Index: 11-40, page 572). 5. Remove the two screws (1) securing the auxiliary tray bracket assembly (2) to the printer frame. 6. Press down the front bottom tray (3) (Asm-Index: 5-5, page 557). 7. Slide the auxiliary tray bracket assembly slightly to the front to release the hooks on the printer frame from the opening in the auxiliary tray bracket assembly. 8. Raise the right end of the auxiliary tray bracket and slide it slightly to the right. 9. Release the left end of the auxiliary tray bracket from the printer frame without pulling the harnesses (4) connected at the left rear of the auxiliary tray bracket. 10. Disconnect J137 of the high harness assembly (Asm-Index: 6-5, page 559) and J222 of the toner relay harness (Asm-Index: 12-18, page 575) from the auxiliary tray bracket. 11. Tilt the auxiliary tray bracket rear side up and remove it from the printer frame.

Replacement
1. 2. 3. 4. Open the front tray cover. Open the Pop up/ROS assembly and keep it open during the following steps. Press down the front bottom tray. Hold the auxiliary tray bracket assembly in one hand and hold the arm of the auxiliary tray no paper actuator (Asm-Index: 5-10, page 557) in the up position using the other hand.

5. Tilt the auxiliary tray bracket rear side up and place the left end of the bracket slightly front from the nal position holding the right end up. 6. Reconnect J137 and J222 and place the harnesses outside of the paper well area. Note: You may need to remove the MCU PWB (See page 526 or 529) to reconnect J137 and J222. After reconnection, replace the MCU PWB.
Chapter 6. Removal Procedures, Adjustments 458

7. Hold the arm of the auxiliary tray no paper actuator up and place the auxiliary tray bracket in the printer frame. 8. 9. 10. 11. Note: Ensure that the auxiliary tray no paper actuator ts into the hole in the front bottom tray. Secure the bracket to the printer frame using two screws (silver, 6mm). Replace the EP cartridge. Close the Pop up/ROS assembly. Close the front tray assembly.

Chapter 6. Removal Procedures, Adjustments 459

Auxiliary Tray No Paper Sensor/Actuator


Asm-Index: 5-9 and 5-10, page 557.
3 5 2
J134

hc2m453f

Figure 50. Auxiliary Tray No Paper Sensor/Actuator Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the auxiliary tray bracket assembly (See page 457). 3. Remove the screw (1) securing the auxiliary tray actuator holder (2) to the auxiliary tray bracket assembly (Asm-Index: 5-7, page 557).

Chapter 6. Removal Procedures, Adjustments 460

4. Remove the actuator holder from the bracket with the no paper sensor (3) and the auxiliary tray no paper actuator (Asm-Index: 5-10, page 557) by lifting the right (sensor) end of the holder to disengage the hook (4) from the auxiliary tray bracket. 5. Disconnect J134 of the auxiliary tray no paper harness (Asm-Index: 5-12, page 557) from the auxiliary tray no paper sensor and remove the harness from the clamp on the auxiliary tray actuator holder (Asm-Index: 5-11, page 557). 6. Holding the arm of the no paper actuator (5) up, squeeze the hooks of the no paper sensor, and remove the sensor from the holder. 7. Push the actuator end (as opposed to the sensor ag end) of the actuator (5) rearwards until it snaps out of the holder.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 461

Toner Sensor Assembly


Asm-Index: 5-13, page 557.

2 1

J221

hc2m975f

Figure 51. Toner Sensor Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the EP cartridge (Asm-Index: 11-40, page 572).
Chapter 6. Removal Procedures, Adjustments 462

3. To remove the entire assembly: a. Snap out the toner sensor holder (Asm-Index: 5-15, page 557). b. Disconnect P/J922 at the left side of the printer. 4. To remove just the toner sensor: a. Using a small at blade screwdriver, expand the hooks (1) on the upper side of the toner sensor holder (2) (Asm-Index: 5-15, page 557) to remove the toner sensor (3) (Asm-Index: 5-14, page 557) from the holder. b. Disconnect J221 of the toner sensor harness (Asm-Index: 5-17, page 557) from the sensor.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 463

Front Bottom Tray


Asm-Index: 5-5, page 557.

1 1

hc2m456f

Figure 52. Front Bottom Tray Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 464

3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray together with the front tray assembly (See page 455). 11. Remove the auxiliary tray bracket assembly (See page 457). 12. Remove the BTR assembly (See page 466) to protect it from damage. 13. Remove the controller assembly (See page 535). 14. Remove the CRU guide assembly left (See page 506). 15. Remove the CRU guide assembly right (See page 510). 16. Lift the left side of the front bottom tray (1) and pull the tray out from under the cams (2) on the ends of the pick up roll assembly (Asm-Index: 6-8, page 559). 17. Lift the left front side of the tray and slide it to the left to remove. 18. Remove the tray. 19. Remove the auxiliary tray normal force springs (3) (Asm-Index: 5-6, page 557) if necessary.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 465

BTR Assembly
Asm-Index: 6-1, page 559.

hc2m461f

Figure 53. BTR Assembly Removal

Chapter 6. Removal Procedures, Adjustments 466

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the front tray assembly (Asm-Index: 5-1, page 557). 3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572). Ensure that it does not close during the operations below. Attention: Do not touch the surface of the roll of the BTR assembly, the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559), or the window of the ROS assembly (Asm-Index: 11-20, page 572). 4. 5. 6. 7. Turn up the levers of the BTR assembly (1) at both ends. Holding the levers, lift the BTR upwards at a 45 degree angle. Remove the BTR from the transport chute assembly. Place the BTR on a secure surface and cover the BTR with paper so as not to contaminate or damage it.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 467

Transport Chute Assembly


Asm-Index: 6-2, page 559.

J14

DTS

1
TR

2 1
J131 P/J135

J121

J124

J13

hc2m462f

Figure 54. Transport Chute Assembly Removal (1)

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 468

4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray together with the front tray assembly (See page 455). 11. Remove the fuser assembly (See page 487). 12. Remove the controller assembly (See page 535). 13. Remove the Pop up/ROS assembly (See page 500). 14. Remove the auxiliary tray bracket assembly (See page 457). 15. Carefully remove the BTR assembly (See page 466). 16. Disconnect J180 of the fuser cover harness from the duplex interface PWB (Asm-Index: 12-6, page 575). 17. Remove the duplex interface PWB (See page 524). 18. Disconnect: a. J13 and J14 of the high harness assembly (Asm-Index: 6-5, page 559) from the MCU PWB. b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of the high harness assembly to the LVPS assembly (Asm-Index: 12-4, page 575) and to the interlock switch (Asm-Index: 12-1, page 575). c. J TR and J DTS of the high harness from the HVPS (Asm-Index: 12-11, page 575). d. J131 from the registration clutch assembly (Asm-Index: 10-9, page 570). e. J135 from the pick up solenoid (Asm-Index: 6-17, page 559).

Chapter 6. Removal Procedures, Adjustments 469

19. Release all harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page 559) from their clamps. 20. Remove the eight screws (1) securing the rear tie plate (2) (Asm-Index: 10-5, page 570). 21. Remove the rear tie plate from the printer body. 22. Place the harnesses and wires to the side of the transport chute assembly. 23. Remove the six screws securing the right CRU guide assembly (Asm-Index: 11-31, page 572). 24. Remove the six screws (3) securing the transport chute (4). 25. Lift the transport chute and remove it from the printer frame.

Chapter 6. Removal Procedures, Adjustments 470

DTS J13 J14 J14 J13 TR DTS J124 TR

3
J124

hc2m463f

Figure 55. Transport Chute Assembly Removal (2)

Replacement
1. Place the transport chute assembly on the printer frame. Attention: Ensure the front bottom tray (Asm-Index: 5-5, page 557) is located under the pick up roll assembly (Asm-Index: 6-8, page 559) and the pick up cams (Asm-Index: 6-12, page 559) presses down the front bottom tray. 2. Secure the transport chute assembly to the printer frame using six screws (silver, collared, 10mm).
Chapter 6. Removal Procedures, Adjustments 471

3. Place the harnesses and wires to the side of the controller assembly (Asm-Index: 13-1, page 578). 4. Route all of the harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page 559) under the clamps. Attention: Route the harnesses so that they do not touch the gears. 5. Place the rear tie plate on the printer body and secure the tie plate using six screws (silver, 6mm) and two screws (gold, self tapping, 8mm). 6. Replace the MCU PWB together with the MCU holder (See page 529). 7. Reconnect: a. J13 and J14 of the high harness assembly to the MCU PWB. b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of the high harness assembly to the LVPS assembly and to the interlock switch. c. J TR and J DTS of the high harness to the HVPS. d. J131 to the registration clutch assembly. e. J135 to the pick up solenoid. 8. Replace the duplex interface PWB (See page 524). 9. Reconnect P/J180 of the fuser cover harness to the duplex interface PWB. 10. Replace the BTR assembly (See page 466). 11. Replace the auxiliary tray bracket assembly (See page 457). 12. Replace the Pop up/ROS assembly (See page 500). 13. Replace the controller assembly (See page 535). 14. Replace the fuser assembly (See page 487). 15. Replace the front in tray together with the front tray assembly (See page 455). 16. Replace the pop up cover assembly (See page 416). 17. Replace the exit cover (See page 414).
Chapter 6. Removal Procedures, Adjustments 472

18. Replace the front side cover (See page 412). 19. Replace the right cover assembly (See page 410). 20. Replace the left cover assembly (See page 406). 21. Replace the right top cover (See page 404). 22. Replace the left top cover (See page 402). 23. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 473

Pick Up Roll
Asm-Index: 6-9, page 559.

hc2m465f

Figure 56. Pick Up Roll Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the auxiliary tray cover (Asm-Index: 5-2, page 557). 3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and ensure it does not close during the operations below.
Chapter 6. Removal Procedures, Adjustments 474

4. Remove the EP cartridge (Asm-Index: 11-40, page 572). 5. Moe the auxiliary tray bracket assembly away from the rolls457), only diconnect the connectors if necessary. 6. If the rolls are not oriented as shown, you may need to rotate the shaft with the following procedure: a. Remove the controller assembly (See page 535). b. Press on the armature of the pick up solenoid (Asm-Index: 6-17, page 559) down to engage the pick up gear (Asm-Index: 6-15, page 559) with the drive. c. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up cams (Asm-Index: 6-12, page 559) are face down. Note: Repeat steps 5 hrough 7 for right and left side rolls. 7. Release the hook on the core roll (1) (Asm-Index: 6-10, page 559) from the groove on the pick up shaft, using a at blade screwdriver or nger nail. Slide the core roll away from the pick up roll (2). 8. Slide the pick up roll in the same direction as step 7 until it is clear of the drive pin on the pick up shaft. 9. Remove the pick up roll from the shaft.

Replacement
Note: Repeat steps 1 through 3 for right and left side rolls. 1. Holding the rubber side of the pick up roll up, place it on the pick up shaft on the outside of the drive pins on the pick up shaft. Attention: The arrows molded into the side of the pick up rolls show the direction of rotation. Be sure to install the rolls correctly. 2. Slide the pick up roll inside inserting the drive pins on the pick up shaft into the grooves on the roll. 3. Pressing down slightly on the retard pad assembly, (Asm-Index: 6-18, page 559), slide the core roll on the same direction as step 2, until its hook snaps into the groove on the pick up shaft.
Chapter 6. Removal Procedures, Adjustments 475

4. Replace the auxiliary tray bracket assembly (See page 457). 5. Replace the EP cartridge. 6. Close the Pop up/ROS assembly.

Chapter 6. Removal Procedures, Adjustments 476

Pick Up Solenoid
Asm-Index: 6-17, page 559.

P/J135

2
hc2m466f

Figure 57. Pick Up Solenoid Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 477

4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Remove the auxiliary tray bracket assembly (See page 457). 11. Press the armature (1) of the pick up solenoid (2) down. 12. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up gear (3) (Asm-Index: 6-15, page 559) stops. 13. Press down again on the armature of the pick up solenoid. 14. Remove the pick up spring (4) (Asm-Index: 6-16, page 559) from the pick up gear and the housing of the transport chute assembly (Asm-Index: 6-2, page 559). 15. Disconnect P/J135 from the harness for the pick up solenoid. 16. Remove the screw (5) securing the solenoid on the transport chute through the opening in the left frame assembly (Asm-Index: 10-11, page 570). 17. Remove the solenoid from the transport chute through the opening in the left frame.

Replacement
1. Place the pick up solenoid in position on the transport chute assembly through the opening in the left frame assembly so that the armature of the pick up solenoid meshes with the pick up gear. 2. Secure the solenoid on the transport chute assembly through the opening in the left frame, using a screw (gold, self tapping, 8mm).

Chapter 6. Removal Procedures, Adjustments 478

3. Reconnect P/J135 to the harness for the pick up solenoid and route the harness so that it does not interfere with the gears. 4. Replace the pick up spring between the pick up gear and the housing of the transport chute assembly. 5. Press the armature of the pick up solenoid down. 6. Rotate the rotor of the main motor clockwise until the pick up gear stops (the rubber side of the pick up rolls are face up). 7. Replace the auxiliary tray bracket assembly (See page 457). 8. Replace the MCU PWB (See page 526) together with the MCU holder. 9. Replace the duplex interface PWB (See page 524). 10. Reconnect J180 to the duplex interface PWB 11. Replace the controller assembly (See page 535). 12. Replace the front side cover (See page 412). 13. Replace the left cover assembly (See page 406). 14. Replace the left top cover (See page 402). 15. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 479

Retard Pad Assembly


Asm-Index: 6-18, page 559.

1
hc2m467f

Figure 58. Retard Pad Assembly Removal (1)

Chapter 6. Removal Procedures, Adjustments 480

Apply the grease

3 5

hc2m468f

Figure 59. Retard Pad Assembly Removal (2)

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the right top cover (See page 404). 4. Remove the right cover assembly (See page 410). 5. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and keep it open during the operation below. 6. Remove the auxiliary tray bracket assembly (See page 457). 7. Remove the two pick up rolls (See page 474).

Chapter 6. Removal Procedures, Adjustments 481

8. Remove the three screws (1) securing the transport front chute (2) (Asm-Index: 6-7, page 559). 9. Release the hook on the center core roll (3) (Asm-Index: 6-10, page 559) and slide the center core roll to the right away from the retard pad assembly (4). Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft (Asm-Index: 6-13, page 559). 10. Press the retard pad assembly to the front and pull its rear side up to release the hooks on its rear side from the transport chute assembly. 11. Hold the retard pad assembly at a right angle and ensure two retard springs (5) (Asm-Index: 6-19, page 559) hang on it. 12. Remove the retard pad assembly together with the two retard springs by pressing to the front. 13. Remove the retard springs from the retard pad assembly.

Replacement
1. Open the Pop up/ROS assembly and keep it open during the operation below. 2. 3. 4. 5. 6. Note: Step 2 is applicable only when installing a new retard pad assembly. Using a small at blade screwdriver apply the grease, packed with the retard pad assembly package, to the bearing groove on the transport chute assembly. Reinstall the retard springs on the retard pad assembly. Hold the surface of the retard pad assembly at a right angle and place it in the hollow of the transport chute assembly together with two retard springs. Position the retard springs in the groove in the hollow of the transport chute assembly using a small at blade screwdriver. Press the retard pad assembly to the front tilting its rear side to insert its rear side into the hollow on the transport chute assembly until the retard pad assembly snaps in place.

Chapter 6. Removal Procedures, Adjustments 482

7. Slide the center core roll to the left until the hook on the core roll snaps in the groove on the pick up shaft. Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft. 8. Place the right side of the transport front chute on the transport chute aligning the position hole in the front chute to the pin on the transport chute together with the grounding plate. 9. Secure the transport front chute using three screws (silver, self tapping, with washer, 8mm). 10. Replace the two pick up rolls (See page 474). 11. Replace the auxiliary tray bracket assembly (See page 457). 12. Close the Pop up/ROS assembly. 13. Replace the right cover assembly (See page 410). 14. Replace the right top cover (See page 404). 15. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 483

Registration Sensor/Actuator
Asm-Index: 7-7, page 562.

P/J132

5 9 1 6 2 5 1

10

3
hc2m472f

Figure 60. Registration Sensor/Actuator Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 484

3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the fuser assembly (See page 487). 10. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it to keep it open without the force of the pop up springs in the next step. 11. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers. 12. Close the Pop up/ROS assembly. 13. Remove the controller assembly (See page 535). 14. Disconnect P/J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 15. Remove the duplex interface PWB (See page 524). 16. Remove screws below: a. Two screws (1) securing the lower part of the back of the rear tie plate (2) to the base frame assembly (Asm-Index: 10-2, page 570), b. Two screws (3) securing the left of the tie plate to the left frame assembly (Asm-Index: 10-11, page 570), c. Two screws (4) securing the right of the tie plate to the right frame assembly (Asm-Index: 10-4, page 570), and d. Two screws (5) securing the upper part of the back of the tie plate to the transport chute assembly (Asm-Index: 6-2, page 559).
Chapter 6. Removal Procedures, Adjustments 485

17. Disconnect P/J132 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration sensor (Asm-Index: 7-6, page 562). 18. Remove the screw (6) securing the registration sensor bracket (7) (Asm-Index: 7-9, page 562) to the transport chute assembly. 19. Remove the registration sensor bracket from the transport chute. 20. Press down the arm of the registration actuator and squeeze the two hooks securing the sensor (8) to the bracket to remove the registration sensor. 21. Turn the registration actuator (9) to match the cutout on its left side shaft with the opening in the frame of the registration sensor bracket. 22. Release the left side shaft of the registration actuator from the bracket. 23. Slide the actuator to the left and remove it from the bracket together with the registration spring (10).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 486

Fuser Assembly
Asm-Index: 8-1, page 564.

3 2

hc2m481f

Figure 61. Fuser Assembly Removal

Chapter 6. Removal Procedures, Adjustments 487

Removal
CAUTION: <2-25> High temperature; switch off the printer and allow at least 20 minutes for parts in this area to cool before handling.
hcsf0225

1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (1) (Asm-Index: 1-1, page 548). 3. Loosen the two captured thumb screws (2) securing the fuser assembly (3) to the left frame assembly (Asm-Index: 10-11, page 570). 4. Lift up the fuser assembly (left end rst), removing the locking tab (4) from the locking bracket (5). Removing the fuser assembly disconnects J142.

Replacement
1. Place the fuser assembly on the top of the printer body, making sure J142 connects properly. 2. Hold the tip of the full stack actuator (Asm-Index: 8-8, page 564) so that it does not interfere with the exit cover (Asm-Index: 1-12, page 548). 3. Secure the fuser assembly to the left assembly using the two captured thumb screws. 4. Close the fuser cover assembly.

Chapter 6. Removal Procedures, Adjustments 488

Main Motor
Asm-Index: 10-6, page 570.

J16

hc2m4a1f

Figure 62. Main motor Removal

Chapter 6. Removal Procedures, Adjustments 489

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 7. Remove the duplex interface PWB (See page 524). 8. Disconnect J16 of the main motor (1) from the MCU PWB (Asm-Index: 12-8, page 575). Attention: Move the main motor to keep from touching the MCU holder (Asm-Index: 12-9, page 575) during steps 9 and 10. 9. Remove the three screws (2) securing the main motor to the left frame assembly (Asm-Index: 10-11, page 570). 10. Remove the main motor from the left frame assembly.

Replacement
Attention: Move the main motor to keep from touching the MCU holder during the following step. 1. Place the main motor in the left frame assembly and secure the motor using three screws (silver, 6mm). 2. Rotate the rotor of the main motor clockwise manually, and ensure it rotates smoothly. 3. Reconnect J16 of the main motor to the MCU PWB. 4. Replace the duplex interface PWB (See page 524). 5. Reconnect J180 of the fuser cover harness to the duplex interface PWB.
Chapter 6. Removal Procedures, Adjustments 490

6. Replace the controller assembly (See page 420). 7. Replace the front side cover (See page 412). 8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 491

Paper Handling Gear Assembly


Asm-Index: 10-7, page 570.

1 2

J131

2
hc2m4a2f

Figure 63. Paper Handling Gear Assembly Removal

Chapter 6. Removal Procedures, Adjustments 492

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Disconnect J131 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration clutch assembly (Asm-Index: 10-9, page 570). 11. Unhook all the wires and harnesses from the clamp on the paper handling gear assembly (1). 12. Remove the three screws (2) securing the paper handling gear assembly. 13. Slightly pull out the gear assembly and release the registration clutch assembly from the drive bearing left (3) (Asm-Index: 10-8, page 570). 14. Remove the gear assembly from the left frame assembly (Asm-Index: 10-11, page 570). 15. Remove the drive bearing left from the gear assembly.

Chapter 6. Removal Procedures, Adjustments 493

Replacement
1. Place the drive bearing left in the paper handling gear assembly. 2. Place the gear assembly in the left frame assembly inserting the shaft of the registration clutch assembly into the drive bearing left. 3. Secure the gear assembly to the left frame using three screws (silver, 6mm). 4. Hook all the wires and harnesses to the clamp on the gear assembly. Attention: Route the wires and harnesses to keep from touching the gears. 5. Reconnect J131 of the high harness assembly to the registration clutch assembly. 6. Replace the MCU PWB. 7. Replace the duplex interface PWB (See page 524). 8. Reconnect J180 of the fuser cover harness to the duplex interface PWB (Asm-Index: 12-6, page 575). 9. Replace the controller assembly (See page 535). 10. Replace the front side cover (See page 412). 11. Replace the left cover assembly (See page 406). 12. Replace the left top cover (See page 402). 13. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 494

Registration Clutch Assembly


Asm-Index: 10-9, page 570.

hc2m4a3f

Figure 64. Registration Clutch Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 495

5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Remove the paper handling gear assembly (See page 492) together with the drive bearing left (Asm-Index: 10-8, page 570). 11. Pull out the registration clutch assembly (1) and remove it from the left frame assembly (Asm-Index: 10-11, page 570).

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 496

Main Gear Assembly


Asm-Index: 10-10, page 570.

hc2m4a4f

Figure 65. Main Gear Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404).
Chapter 6. Removal Procedures, Adjustments 497

5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray (See page 455) including the front tray assembly (Asm-Index: 5-1, page 557). 11. Remove the BTR assembly (See page 466). 12. Remove the fuser assembly (See page 487). 13. Remove the controller assembly (See page 535). 14. Remove the duplex interface PWB (See page 524). 15. Remove the MCU PWB (See page 526) together with MCU holder (Asm-Index: 12-9, page 575). 16. Remove the main motor (See page 489). 17. Remove the paper handling gear assembly (See page 492) together with the drive bearing left (Asm-Index: 10-8, page 570). 18. Remove the registration clutch assembly (See page 495). 19. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) to a right angle and hold it in your hand to keep from closing without the force of the pop up spring left/right (Asm-Index: 11-6 and 11-7, page 572) in the next step. 20. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers. 21. Close the Pop up/ROS assembly. 22. Remove the eight screws securing the rear tie plate (Asm-Index: 10-5, page 570). 23. Remove the four screws (1) securing the main gear assembly (2) to the left frame assembly (Asm-Index: 10-11, page 570).
Chapter 6. Removal Procedures, Adjustments 498

24. Slide the main gear assembly to the right and release gears and shafts from the frame. If you are having trouble removing the main gear assembly, remove the CRU guide assembly left (See page 506). 25. Pull the gear assembly up and behind to remove it from the frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 499

Pop Up Unit
Asm-Index: 11-111-23, page 572.
2 3 8 4 7
FRONT

1 9 5 6

J12

J17

hc2m977f

Figure 66. Pop Up Unit Removal (2)

Chapter 6. Removal Procedures, Adjustments 500

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the exit cover (See page 414). 7. Remove the pop up cover assembly (See page 416). 8. Remove the fuser assembly (See page 487). 9. Remove the controller assembly (See page 535). 10. Disconnect J12 of the ROS harness (Asm-Index: 12-16, page 575) and J17 of the CRU sensor assembly (Asm-Index: 11-15, page 572) from the MCU PWB (Asm-Index: 12-8, page 575). 11. Remove the ferrite core 1 (1) (Asm-Index: 12-21, page 575) from the harnesses using a small at blade screwdriver 12. Remove the screw (2) securing the pop up earth wire (3) (Asm-Index: 11-25, page 572) to the pop up frame (4) (Asm-Index: 11-1, page 572). Note: The screw securing the other end of the pop up earth wire to the left frame assembly (Asm-Index: 10-11, page 570) does not need to be removed. 13. Remove the screw (5) securing the clamp P (6) (Asm-Index: 12-22, page 575) to the left frame assembly and release the ROS harness and the harness of the CRU sensor assembly 14. Release the ROS harness and the harness of the CRU sensor assembly from the opening in the left frame.

Chapter 6. Removal Procedures, Adjustments 501

Attention: Do not touch the surface of the BTR assembly (Asm-Index: 6-1, page 559), the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following step. 15. Open the Pop up/ROS assembly and hold it even, the spring force is released in next step. 16. Release the pop up spring left (7) /right (8) (Asm-Index: 11-6 and 11-7, page 572) from the rear tie plate (Asm-Index: 10-5, page 570). 17. Close the Pop up/ROS assembly. 18. Remove the two screws (9) securing the pop up shaft (Asm-Index: 11-2, page 572) to the left frame assembly and the right frame assembly (Asm-Index: 10-4, page 570) respectively. 19. Lift the Pop up/ROS assembly and slide it along the guide channel and remove the pop up unit from the printer frame.

Replacement
Reverse the Removal procedure. Note: Ensure that the fuser guide lever is above the metal tab of the fuser drive gear as shown in Figure 66 on page 500.

Chapter 6. Removal Procedures, Adjustments 502

CRU Sensor Assembly


Asm-Index: 11-15, page 572.
2

P/J171

J17

hc2m4b3f

Figure 67. CRU Sensor Assembly Removal

Chapter 6. Removal Procedures, Adjustments 503

Removal
Note: If you can access the four mounting screws, you may be able to avoid complete removal of the Pop up/ROS assembly. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the front side cover (See page 412). 7. Remove the exit cover (See page 414). 8. Remove the pop up cover assembly (See page 416). 9. Remove the fuser assembly (See page 487). 10. Remove the controller assembly (See page 535). 11. Remove the Pop up/ROS assembly (See page 500). 12. Lay the Pop up/ROS assembly upside down. 13. Release the harness of the CRU sensor assembly (1) from the clamp. 14. Release the ROS harness (Asm-Index: 12-16, page 575) from the clamp, if necessary. 15. Remove the four screws (2) securing the CRU sensor assembly to the pop up frame (Asm-Index: 11-1, page 572) and remove the sensor assembly. 16. Disconnect P/J17 from the MCU.

Chapter 6. Removal Procedures, Adjustments 504

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 505

CRU Guide Assembly Left


Asm-Index: 11-30, page 572.

6 5

6
hc2m4b7f

Figure 68. CRU Guide Assembly Left Removal

Chapter 6. Removal Procedures, Adjustments 506

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Remove the controller assembly (See page 535). 10. Remove the center screw (1) of the HVPS (Asm-Index: 12-11, page 575) securing the HVPS to the CRU guide assembly left (2). 11. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the operation below. 12. Remove the two screws securing the left and right pop up latch feet (Asm-Index: 11-22, page 572) to the left and right pop up latches (Asm-Index: 11-10 and 11-11, page 572). 13. Flex the left and right pop up latches and remove the left and right pop up latch feet. 14. Open the Pop up/ROS assembly. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) or the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 15. Remove the BTR assembly (See page 466) to protect it from damage.

Chapter 6. Removal Procedures, Adjustments 507

16. Remove the screw (3) securing the earth plate left (4) (Asm-Index: 11-32, page 572) on the top of the CRU guide assembly left. 17. Remove the screw (5) securing the upper part of the CRU guide assembly left. 18. Remove the six screws (6) securing the CRU guide assembly. 19. Press the pins on the left side of the left frame assembly (Asm-Index: 10-11, page 570) to release the guide assembly. 20. Remove the guide assembly by carefully working it away from the printer frame.

Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly or the window of the ROS assembly during the following steps. 2. Place the CRU guide assembly left on the left frame assembly inserting the pins on the guide assembly into the openings in the printer frame. 3. Secure the guide assembly using six screws (silver, 8mm). 4. Secure the upper part of the guide assembly using a screw (gold, 14mm). 5. Secure the earth plate left using a screw (silver, 6mm) 6. Replace the BTR assembly (See page 466). 7. Half close the Pop up/ROS assembly. 8. Flex the pop up latch left/right and place the left and right pop up latch foot on the latch left/right. You may rotate the latch foot to position it properly. 9. Secure the left and right pop up latch foot to the pop up latch left/right using two screws (gold, self-tapping, 10mm). 10. Close the Pop up/ROS assembly.

Chapter 6. Removal Procedures, Adjustments 508

Attention: Ensure that the earth plate left contacts the pop up frame (Asm-Index: 11-1, page 572). 11. Secure the HVPS to the guide assembly using a screw (gold, self tapping, 8mm) on the center of the HVPS. 12. Replace the controller assembly (See page 535). 13. Replace the BTR assembly (See page 466). 14. Replace the front in tray (See page 455) together with the front tray assembly. 15. Replace the front side cover (See page 412). 16. Replace the right cover assembly (See page 410). 17. Replace the left cover assembly (See page 406). 18. Replace the right top cover (See page 404). 19. Replace the left top cover (See page 402). 20. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 509

CRU Guide Assembly Right


Asm-Index: 11-31, page 572.

hc2m4b8f

Figure 69. CRU Guide Assembly R Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).

Chapter 6. Removal Procedures, Adjustments 510

4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the operation below. 10. Remove the BTR assembly (See page 466) to protect from damage. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 11. Remove the screw (1) securing the earth spring right (2) (Asm-Index: 11-33, page 572) to the CRU guide assembly right (3) and remove the spring. 12. Remove the ve screws (4) securing the rear left end and front left side of the guide assembly. 13. Press the pins on the right side of the right frame assembly (Asm-Index: 10-4, page 570) to release the guide assembly. 14. Remove the guide assembly from the printer frame.

Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROS assembly during the following steps. 2. Place the guide assembly on the right frame assembly inserting pins on the guide assembly into the openings.
Chapter 6. Removal Procedures, Adjustments 511

3. Secure the guide assembly using ve screws (silver, 8mm). 4. Secure the earth spring right to the guide assembly using a screw (gold, collared, 12mm). 5. Replace the BTR assembly (See page 466). 6. Close the Pop up/ROS assembly. Attention: Ensure that the earth spring right contacts the pop up frame (Asm-Index: 11-1, page 572). 7. Replace the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 8. Replace the front side cover (See page 412). 9. Replace the right cover assembly (See page 410). 10. Replace the left cover assembly (See page 406). 11. Replace the right top cover (See page 404). 12. Replace the left top cover (See page 402). 13. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 512

Interlock Switch
Asm-Index: 12-1, page 575.

hc2m4c1f

J21 J123

Figure 70. Interlock switch Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 513

3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Remove the BTR assembly (See page 466) to protect it from damage. 10. Remove the controller assembly (See page 535). 11. Remove the CRU guide assembly left (See page 506). 12. Disconnect J123 of the interlock switch (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and J21 of the interlock switch on the MCU PWB (Asm-Index: 12-8, page 575) and release the harnesses from the clamps. 13. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the following steps. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 14. Remove the screw (2) securing the interlock switch (Asm-Index: 12-1, page 575) to the left frame assembly (Asm-Index: 10-11, page 570). 15. Release the harness through the opening in the printer frame and remove the interlock switch from the frame.

Chapter 6. Removal Procedures, Adjustments 514

Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROS assembly during the following steps. 2. Insert the harness through the opening in the left frame assembly and place the interlock switch on the frame matching the position of the pin on the frame to the hollow on the switch. 3. Secure the interlock switch to the frame using a screw (gold, 12mm). Attention: Ensure that the arm on the pop up frame presses the interlock switch when the Pop up/ROS assembly closes. 4. Reconnect J123 of the interlock switch to the LVPS and J21 of the interlock switch to the MCU PWB and attach the harnesses to the clamps. 5. Replace the CRU guide assembly left (See page 506). 6. Replace the controller assembly (See page 535). 7. Replace the BTR assembly (See page 466). 8. Replace the front in tray (See page 455) together with the front tray assembly. 9. Replace the front side cover (See page 412). 10. Replace the right cover assembly (See page 410). 11. Replace the left cover assembly (See page 406). 12. Replace the right top cover (See page 404). 13. Replace the left top cover (See page 402). 14. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 515

Fuser Cover Switch


Asm-Index: 12-2, page 575.

J190

2 1 1

hc2m4c2f

J190

Figure 71. Fuser Cover switch Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 516

4. 5. 6. 7.

Remove the fan. Remove the fan duct. Using a at-bladed screwdriver, squeeze the hooks securing the switch to the printer frame. Disconnect J190 of the fuser cover harness (Asm-Index: 12-13, page 575) from the fuser cover switch (Asm-Index: 12-2, page 575) and remove the switch.

Replacement
1. 2. 3. 4. 5. Press the cover switch up into the opening until the switch snaps into place. Reconnect J190 of the fuser cover harness to the fuser cover switch. Replace the fan duct. Replace the fan. Replace the left top cover (See page 402).

6. Replace the fuser cover assembly (See page 400). Attention: Ensure that the fuser cover assembly (Asm-Index: 1-1, page 548) pushes the tab of the fuser cover switch when the cover is closed.

Chapter 6. Removal Procedures, Adjustments 517

Fan
Asm-Index: 12-3, page 575.

J122

hc2m3c3f

Figure 72. fan Removal

Chapter 6. Removal Procedures, Adjustments 518

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J122 of the fan (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and remove the ferrite core1 (Asm-Index: 12-21, page 575) from the harness. 8. Release the harness of the fan from clamp and opening. 9. Remove the two screws (2) securing the fan to the printer frame. 10. Remove the fan.

Replacement
1. Place the fan in the printer frame so the label faces out, so that the air blows out. 2. Secure the fan to the printer frame using two screws (silver, collared, 10mm). 3. Reconnect J122 of the fan to the LVPS assembly and reinstall the ferrite core1 into the ROS harness (Asm-Index: 12-16, page 575), the harness for the CRU sensor assembly (Asm-Index: 11-15, page 572), the fuser cover harness (Asm-Index: 12-13, page 575) and the harness to the fan. 4. Route the harness of the fan hanging to clamp and passing through opening so as not to interfere with gears and without slack. 5. Replace the controller assembly (See page 535). 6. Replace the front side cover (See page 412). 7. Replace the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 519

8. Replace the left top cover (See page 402). 9. Replace the fuser cover assembly (See page 400).

Chapter 6. Removal Procedures, Adjustments 520

LVPS Assembly
Asm-Index: 12-4, page 575.

7
J122 J127 J123

J121

4 1 2

J126

10

5 3
hc2m4C4F

Figure 73. LVPS Assembly Removal

Chapter 6. Removal Procedures, Adjustments 521

Removal
Note: The small fan shown in Figure 73 may not be on later versions of the printer. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the left lower cover (See page 408). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect all the connectors from the LVPS assembly. 8. Release all the harnesses and the wire from their clamps. 9. Remove the screw (1) securing the grounding wires to the printer frame. Attention: Do not move the parts far, since the power inlet and the LVPS assembly (2) are connected by wires. 10. Remove the three screws (3) securing the inlet holder (4) (Asm-Index: 12-5, page 575) to the left frame assembly (Asm-Index: 10-11, page 570). 11. Remove the inlet holder from the printer frame together with the main power switch / power inlet (5). 12. Remove the two screws (6) securing the main power switch / power inlet of the LVPS assembly (2) to the inlet holder and remove the switch/inlet. 13. Remove the four screws (7) securing the circuit board of the LVPS assembly. 14. Carefully remove the LVPS from the printer frame by moving the LVPS slightly to the left and then lifting and pivoting the bottom of the LVPS up to clear the printer frame.

Chapter 6. Removal Procedures, Adjustments 522

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 523

Duplex Interface PWB


Asm-Index: 12-6, page 575.

J180

2 1
hc2m4c5f

Figure 74. Duplex Interface PWB Removal

Chapter 6. Removal Procedures, Adjustments 524

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover. 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (1). 8. Remove the two screws (2) (silver, hexagon, 8mm) securing the rear end of the duplex interface PWB to the left frame assembly (Asm-Index: 10-11, page 570). 9. Pull out the duplex interface PWB to the left to disconnect P/J18 from the MCU PWB (Asm-Index: 12-8, page 575). 10. Remove the duplex interface PWB.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 525

MCU PWB without MCU Holder


Asm-Index: 12-8, page 575.

1 3

2
hc2m4c6f

Figure 75. MCU PWB Removal (1)

Chapter 6. Removal Procedures, Adjustments 526

Removal
Note: If possible, print a CONFIG page before replacing the MCU (see Conguration Page on page 250). After replacing the MCU, the page count value will be reset to 0. This means that the true printer page count will be the value before MCU replacement plus the value shown on the CONFIG page after replacement. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Remove the duplex interface PWB (See page 524). 7. Disconnect all the connectors from the MCU PWB (1) (Asm-Index: 12-8, page 575). 8. Remove the four screws (2). 9. Remove the MCU PWB.

Replacement
1. 2. 3. 4. 5. 6. Position the MCU PWB in the holder. Secure the MCU PWB to the frame using three screws. Secure two clamp Fs to the MCU PWB using a screw. Reconnect all the connectors to the MCU PWB. Route the harnesses to keep from touching the gears and edge of the frame. Replace the duplex interface PWB (See page 524).

7. Replace the controller assembly (See page 535).


Chapter 6. Removal Procedures, Adjustments 527

8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402). Note: The next stes are applicable if you installed a new MCU PWB. 11. Reset the Toner and Fuser counters to 0 (see Counters on page 255). 12. See S/N = 00-00000 (Serial Number) on page 305 to update the serial number in the new MCU PWB. See Figure 5 on page 363 for the location of the serial number on the rear of the printer.

Chapter 6. Removal Procedures, Adjustments 528

MCU PWB with MCU Holder


Asm-Index: 12-8 and 12-9, page 575.

3 2 1 2

hc2m4c7f

Figure 76. MCU PWB Removal (2)

Chapter 6. Removal Procedures, Adjustments 529

Removal
Note: If possible, print a CONFIG page before replacing the MCU (see Conguration Page on page 250). After replacing the MCU, the page count value will be reset to 0. This means that the true printer page count will be the value before MCU replacement plus the value shown on the CONFIG page after replacement. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the duplex interface PWB (See page 524). Note: The models equipped with the controller inside the printer do not use the connectors P19 and P23. The models equipped with the controller outside of the printer do not use connector P23. 8. Disconnect all the connectors from the MCU PWB (1). 9. Release all the harnesses from the clamp and the clamp Fs (Asm-Index: 12-23, page 575) on the MCU holder. 10. Remove the four screws (2) securing the MCU holder (3) to the left frame assembly (Asm-Index: 10-11, page 570). 11. Remove the MCU PWB together with the MCU holder.

Chapter 6. Removal Procedures, Adjustments 530

Replacement
1. Keeping the harness for P/J13 to the printer frame side from the MCU PWB, place the MCU PWB on the left frame assembly together with the MCU holder. 2. Secure the MCU holder to the frame using four screws (gold, 6mm). 3. Reconnect all the connectors to the MCU PWB. 4. Hook the harnesses to the clamp and the clamp Fs on the MCU holder. 5. Route the harnesses to keep from touching the gears and edge of the frame. 6. Replace the duplex interface PWB (See page 524). 7. Replace the controller assembly (See page 535). 8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402). 11. Replace the fuser cover assembly (See page 400). Note: Steps 12 and 13 are applicable if you installed a new MCU PWB. 12. Set the NVRAM data according to the specication of the printer. 13. Reset the Toner and Fuser counters to 0 (see Counters on page 255).

Chapter 6. Removal Procedures, Adjustments 531

HVPS
Asm-Index: 12-11, page 575.
1 3

DTS

2 3
J151

TR

3
hc2m4c8f

Figure 77. HVPS Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 532

4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Disconnect all the connectors from the HVPS (1). Attention: Do not touch the adjustment knob on the HVPS. Do not deform the spring plate on the CRU guide assembly left (Asm-Index: 11-30, page 572). 7. Remove the screw (2) securing the center of the HVPS to the CRU guide assembly left. 8. Remove the four screws (3) securing the HVPS to the left frame assembly (Asm-Index: 10-11, page 570). 9. Remove the DTS and interlock cable holders from the front left frame. 10. Holding the adjustment knob (4) (Asm-Index: 12-12, page 575) in your ngers, remove the HVPS from the frame. 11. Remove the adjustment knob from the HVPS.

Replacement
1. Place the adjustment knob on the HVPS. Attention: Do not change the adjustments on the HVPS. Do not deform the spring attachment on the CRU guide assembly left. 2. Holding the volume knob in your ngers, place the HVPS in the left frame assembly. 3. Secure the HVPS to the frame using four screws (6mm). Attention: Ensure that the spring plate on the CRU guide assembly left touches the terminal on the HVPS. 4. Secure the center of the HVPS to the CRU guide assembly left using a screw (gold, 8mm). 5. Reconnect all the connectors to the HVPS. 6. Route harnesses to keep from touching the gears and frame edges. 7. Replace the controller assembly (See page 535).

Chapter 6. Removal Procedures, Adjustments 533

8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402).

Chapter 6. Removal Procedures, Adjustments 534

Controller Assembly
Asm-Index: 13-1, page 578.
2
J31 J31
|

3 4

hc2m4d1f

Figure 78. Controller Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 535

3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Disconnect J126 from the LVPS assembly (See Figure 73 on page 521). 6. Remove the three screws (2) securing the controller upper cover plate (3) (Asm-Index: 13-9, page 578) to the printer frame. 7. Remove the six screws (4) securing the controller assembly to the left frame assembly (Asm-Index: 10-11, page 570). 8. Remove the controller assembly so that the controller harness (Asm-Index: 13-5, page 578) passes the opening in the frame. Note: J31 is disconnected by removing the controller assembly from the left frame assembly.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 536

Controller PWB
Asm-Index: 13-6, page 578.

5 3

2 5 1 4
hc2m4d2f

Figure 79. Controller PWB Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).

Chapter 6. Removal Procedures, Adjustments 537

4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the two screws (2) securing the external interface connector of the controller PWB. 8. Remove the two screws (3) securing the rear panel (4) (Asm-Index: 13-3, page 578) to the left frame assembly (Asm-Index: 10-11, page 570). 9. Remove the rear panel from the left frame assembly. 10. Remove eleven screws (5) securing the controller PWB to the frame. 11. Remove the controller PWB from the frame.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 538

Controller PWB SIMM

45

Notch

Notch

Flash memory, IPDS SIMMs

DRAM SIMMs

hc2m133F

Figure 80. Controller PWB SIMM Removal

Removal
Attention: Follow the instructions for handling static-sensitive devices described on page 20. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left cover assembly (See page 406). 3. Locate the correct socket group for the type of SIMM you are installing. There are two socket groups: one contains three sockets, the other contains four sockets. The DRAM SIMMs (memory) must are in one of

Chapter 6. Removal Procedures, Adjustments 539

the sockets in the socket group of three. The IPDS SIMM and the ash memory SIMMs (including the Controller SIMM with the operating system, PCL and PS) are in one of the sockets in the socket group of four. SIMMs should be loaded from the left to the right but the position of the SIMM within the group of sockets does not matter. 4. Using your thumbs, press with even pressure on both ends of the clips until the SIMM is released. Pivot the SIMM 45 degrees and remove it from the socket.

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 540

Network Interface Card

hc2m134F

Figure 81. Network Interface Card Removal

Removal
Attention: Follow the instructions for handling static-sensitive devices described on page 20. 1. Switch off printer power and unplug the power cord from the wall. 2. Move to the back of the printer. Two slots for interface cards are located at the right side of the back of the printer. 3. Loosen and remove the thumbscrews that hold the network interface cards. 4. Slide the card from the slot guides, pulling slowly, and remove it from the printer.

Chapter 6. Removal Procedures, Adjustments 541

Replacement
Reverse the Removal procedure.

Chapter 6. Removal Procedures, Adjustments 542

Chapter 7. Preventive Maintenance and Usage Kit


Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543 Usage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543 Reconditioning Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543

Preventive Maintenance
There is no preventive maintenance for the IBM InfoPrint 20.

Usage Kit
The parts included in this kit should all be replaced approximately every 200K prints. The failure of these parts can impair printer performance. The customer is responsible for replacing the Usage Kit. See Appendix B. Supplies on page 591 for ordering information and part numbers. See the IBM InfoPrint 20: Users Guide for replacement instructions.

Reconditioning Kit
There is no reconditioning kit for the IBM InfoPrint 20.

Copyright IBM Corp. 1998

543

Chapter 8. Parts Catalog


How to Use the Parts Catalog . . . . . . . . . . . Assembly-Index . . . . . . . . . . . . . . . . . Grid . . . . . . . . . . . . . . . . . . . . . . . Part Number . . . . . . . . . . . . . . . . . . . Units . . . . . . . . . . . . . . . . . . . . . . . Description. . . . . . . . . . . . . . . . . . . . Assembly Locations . . . . . . . . . . . . . . . . Assembly 1: Covers . . . . . . . . . . . . . . . Assembly 2: Paper Cassette. . . . . . . . . . . Assembly 3: Paper Feeder I . . . . . . . . . . . Assembly 4: Paper Feeder II . . . . . . . . . . Assembly 5: Multi-Sheet Inserter (Auxiliary Tray) Assembly 6: Paper Transportation I . . . . . . . Assembly 7: Paper Transportation II . . . . . . . Assembly 8: Fuser and Paper Exit I . . . . . . . Assembly 9: Fuser and Paper Exit II . . . . . . Assembly 10: Fuser and Drive. . . . . . . . . . Assembly 11: Pop Up and Xerographics. . . . . Assembly 12: Electrical I. . . . . . . . . . . . . Assembly 13: Electrical II . . . . . . . . . . . . Assembly 99: Kits . . . . . . . . . . . . . . . . Assembly 100: Firmware . . . . . . . . . . . . Miscellaneous Items . . . . . . . . . . . . . . . . Commonly Used Parts . . . . . . . . . . . . . . Commonly Used Fasteners . . . . . . . . . . . Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546 .546 .546 .547 .547 .547 .548 .548 .550 .553 .555 .557 .559 .562 .564 .567 .570 .572 .575 .578 .580 .585 .587 .587 .588 .588

Copyright IBM Corp. 1998

544

Cleaners and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588

Chapter 8. Parts Catalog 545

How to Use the Parts Catalog


The parts catalog illustrations and tables show and list all parts of the associated assembly. Below is an example of these tables with an explanation.
Asm Index 1 1 2 3 4 B2 C1 C2 C1 Grid Part Number NP 90H0000 90H0001 NP NP 1 1 1 1 Units Cover asm. v Cover, delivery v Hinge, stopper (with 1-3 and 1-4) v v Guide, left v v Cover, block, front Description

Assembly-Index
All parts of assembly number 1 are listed in this column. The numbers 1, 2, 3, and 4, and so forth refer to the corresponding numbers in the illustration for this assembly. Index number 2, part number 90H0001, is a subassembly of assembly 1. Notice that index number 2 includes two parts, 3 and 4. These parts cannot be ordered individually. If one is needed, order the subassembly, index number 2.

Grid
Each parts illustration is divided into grids. The grids are labeled A, B, C, and D vertically and 1, 2, and 3 horizontally. The combination of a vertical grid (such as C) and a horizontal grid (such as 1) provides the coordinates C1. The index number of the part will be located in the C1 area.

Chapter 8. Parts Catalog 546

Part Number
This is the IBM part number. NP (non procurable) means the part or assembly cannot be ordered.

Units
The number in this column represents the number of usages of that part in this assembly.

Description
This is a description of the assembly or part.

Chapter 8. Parts Catalog 547

Assembly Locations Assembly 1: Covers


1 2 3 4

hc2m301F

Chapter 8. Parts Catalog 548

Table 66. Assembly 1: Covers


Asm Index 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 A3 A3 A2 B4 B1 B1 B2 C1 C4 C1 B4 A2 B2 A2 A2 A1 A1 90H0754 90H0755 90H3329 90H3383 07L0038 NP NP 90H0759 90H0760 90H0761 90H0762 90H0763 90H0764 90H0765 90H0766 90H3466 90H0768 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Covers Fuser cover Fuser cap cover Left top cover Right top cover Left cover assembly (with 1-7, 1-8) v Left side cover v Controller shield Left lower cover Right cover assembly Front side cover Exit cover Pop up upper cover Pop up lower cover Exit extent tray Tray stopper Console assembly and Overlay Console ground wire (Early models only) Description

AsmIndex numbers not used: 1, 13

Chapter 8. Parts Catalog 549

Assembly 2: Paper Cassette


1 2 3 4

1 (with 2-24)

hc2m302F

Chapter 8. Parts Catalog 550

Table 67. Assembly 2: Paper Cassette


Asm Index 2 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 C1 C1 B3 C4 A2 A3 A2 A3 C2, C3 C3 A1 A1 A1, A2 B1 B2 A2 A2 A2 C2 90H0719 90H0718 NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP 1 1 1 1 1 2 1 1 2 1 1 1 2 1 1 1 1 1 1 Grid Part Number Units Paper cassette A3 Long cassette assembly (with 2-22-24) A4 Short cassette assembly (with 2-22-24) v Cassette housing v Cassette bottom cover v Side guide grip v Snubber guide v Side guide assembly L v Side guide assembly R v Rack gear v Pinion gear v Bottom plate assembly v Normal force spring plate v Cassette side normal force spring v Cassette normal force spring v End guide plate v Paper end guide v End guide spring v End guide v Pivot plate Description

Chapter 8. Parts Catalog 551

Table 67. Assembly 2: Paper Cassette (continued)


Asm Index 2 19 20 21 22 23 24 25 25 C2 B1 B2 B1 C3 B1, B3 C1 C1 NP NP NP NP NP NP 90H0770 90H3467 1 1 1 1 1 2 1 1 Grid Part Number Units Paper cassette v Sector gear v Size cam v Locking pin v Cassette latch L v Cassette latch R v Cassette latch spring A3 Cassette cover A4 Cassette cover Description

Chapter 8. Parts Catalog 552

Assembly 3: Paper Feeder I


1 2 3 4

6 (with 7-12, 18)

hc2m303F

Chapter 8. Parts Catalog 553

Table 68. Assembly 3: Paper Feeder I


Asm Index 3 1 2 4 5 6 7 8 9 10 11 12 18 13 14 15 16 A4 B4 C2 C2 B3 B4 C4 B4 B3 C3 C4 C3 B1 B2 B2 B2 90H0771 90H0772 90H0773 90H0774 90H0775 NP NP NP NP 90H0776 NP NP 90H0777 NP NP 90H0778 1 1 1 1 1 1 4 1 1 1 1 1 1 1 1 1 Grid Part Number Units Paper Feeder Feeder PWB Feeder harness (Tray Lower) Turn in chute Turn chute assembly Cassette guide assembly left (with 3-73-12, 3-18) v Cassette guide L v Size actuator v Size actuator spring v Low paper actuator v MSI/Cassette no paper sensor v Feeder harness v Cassette guide cap Cassette guide assembly right (with 3-14, 3-15) v Cassette guide R v Cassette stopper spring Cassette no paper actuator Description

AsmIndex numbers not used: 3, 17

Chapter 8. Parts Catalog 554

Assembly 4: Paper Feeder II


1 2 3 4

hc2m304F

Chapter 8. Parts Catalog 555

Table 69. Assembly 4: Paper Feeder II


Asm Index 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 C2 C2 B4 B4 B4 A3, B1 B4 A4 B4 C2 C2 B4 A1, B1, B3, B4 B3 B4 C4 90H0786 90H0782 90H0783 90H0784 90H0785 90H0780 4 1 1 1 1 2 1 1 1 1 1 2 4 1 1 2 Grid Part Number Units Paper feeder II Feed roll (in kit P/N 90H0779) (see page 580) Feed shaft assembly Feed core (in kit P/N 90H0781) (see page 580) Feed core spring (in kit P/N 90H0781) (see page 580) Feed gear (in kit P/N 90H0781) (see page 580) Feed bearing (in kit P/N 06L9997) (see page 580) Feed spring (in kit P/N 90H0781) (see page 580) Feed solenoid Electromagnetic clutch Turn roll assembly Rear roll assembly Turn gear (in kit P/N 90H3384) (see page 580) Turn bearing Turn idler gear (in kit P/N 90H3384) (see page 580) Feed idler gear (in kit P/N 90H3384) (see page 580) Out idler gear (in kit P/N 90H3384) (see page 580) Description

Chapter 8. Parts Catalog 556

Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)


1 2 3
13 (with 14-17)

7 (with 8-17)

hc2m305F

Chapter 8. Parts Catalog 557

Table 70. Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)


Asm Index 5 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 C2 C2 C2 C3 A1 A3 B4 B4 A4 A4 A4 A4 A3 A3 A3 A3 A3 90H0793 NP 90H0776 90H0794 NP NP 90H0795 NP NP NP NP 90H0790 NP NP 90H0791 90H0792 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Multi-Sheet Inserter Front tray assembly (with 5-2, 5-3) v Front tray cover v Front extent tray Front in tray Front bottom tray Normal force spring (in kit P/N 90H3380) (see page 580) MSI Bracket assembly (with 5-85-17) v Sensor bracket v MSI No paper sensor (same as 3-11) v MSI No paper actuator v MSI actuator holder v MSI no paper harness v Toner sensor assembly (with 5-145-17) v v Toner sensor v v Toner sensor holder v v Toner sensor spring v v Toner sensor harness Description

Chapter 8. Parts Catalog 558

Assembly 6: Paper Transportation I


1 2 3
2 (with 3-19)

8 (with 9-13)

hc2m306F

Chapter 8. Parts Catalog 559

Table 71. Assembly 6: Paper Transportation I


Asm Index 6 1 2 2 3 4 5 5 6 7 8 9 10 12 13 14 15 16 17 A2 A3 A3 B4 A4 A4 A4 A3 B2 C3 C3 C2, C3, C4 C2, D4 C3 C4 C2 C2 B2 90H0799 90H0796 90H0797 90H3421 NP NP 11L5354 11L6539 NP NP NP 90H0798 NP NP NP NP 1 1 1 1 1 1 1 1 1 1 2 3 2 1 1 1 1 1 Grid Part Number Units Paper transportation I BTR assembly (Supply Item - Included in Usage Kit) Transport chute assembly 100/110V (with 6-36-19) Transport chute assembly 220V (with 6-36-19) v Transport sub assembly (same as 7-1) v Connector bracket2 v High harness assembly (100V/110V) v High harness assembly (220V) v Transport out plate v Transport front chute v Pick up roll assembly (with 6-96-13) v v Pick up roll v v Core roll v v Pick up cam v v Pick up shaft v Transport bearing v Pick up gear (in kit P/N 90H3384) (see page 580) v Pick up spring (in kit P/N 90H3380) (see page 580) v Pick up solenoid Description

Chapter 8. Parts Catalog 560

Table 71. Assembly 6: Paper Transportation I (continued)


Asm Index 6 18 19 B2 B3 1 2 Grid Part Number Units Paper transportation I v Retard pad (in kit P/N 90H0800) (see page 580) v Retard pad spring (in kit P/N 90H0800) (see page 580) Description

AsmIndex numbers not used: 11

Chapter 8. Parts Catalog 561

Assembly 7: Paper Transportation II


1 2
1 (with 2-19)

hc2m307F

Chapter 8. Parts Catalog 562

Table 72. Assembly 7: Paper Transportation II


Asm Index 7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 B2 B3 A2, A4 A2 A4 A2 A2 A3 A3 C2 B2 B1 C3 C3 B1, C3 B1, B3 B2 B3 C2 07L0044 07L0044 90H3293 90H3291 90H3292 NP NP 11L5337 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 1 Grid Part Number Units Paper transportation II Transport sub assembly (with 7-27-19) (same as 6-3) v Transport housing assembly v BTR bearing v BTR spring left (in kit P/N 90H3380) (see page 580) v BTR spring right (in kit P/N 90H3380) (see page 580) v Registration sensor (in kit P/N 90H3290) (see page 580) v Registration actuator (in kit P/N 90H3290) (see page 580) v Registration spring (in kit P/N 90H3290) (see page 580) v Registration sensor bracket (in kit P/N 90H3290) (see page 580) v Metal registration roll v Rubber registration roll v Registration in gear (in kit P/N 90H3384) (see page 580) v Registration back gear (in kit P/N 90H3384) (see page 580) v Registration front gear (in kit P/N 90H3384) (see page 580) v Registration front bearing (in kit P/N 06L9997) (see page 580) v Registration back bearing (in kit P/N 06L9997) (see page 580) v Registration spring left v Registration spring right v Rear chute assembly Description

Chapter 8. Parts Catalog 563

Assembly 8: Fuser and Paper Exit I


1 2 3
1 (with 2-28)

28
A A

10 (with 11-14)

27
B B

26
C C

hc2m308F

Chapter 8. Parts Catalog 564

Table 73. Assembly 8: Fuser and paper exit I


Asm Index 8 1 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 A3 A3 A3 C3 B2 C4 A1 A1 A2 A2 A2 A3 A3 A2 B2 B2 B2 NP NP NP NP NP NP 90H3465 90H0750 90H0751 NP NP NP NP NP NP NP 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Fuser and paper exit Fuser sub-assembly 100V (with 8-28-28, including BTR Assembly 90H0796) Supply Fuser sub-assembly 110V (with 8-28-28, including BTR Assembly 90H0796) Supply Fuser sub-assembly 220V (with 8-28-28, including BTR Assembly 90H0796) Supply v Fuser sub assembly (same as 9-1) v Fuser cover L v Fuser cover R v Fuser label assembly v Fuser top cover assembly v Full stack sensor v Full stack actuator v Full stack spring (in kit P/N 90H3380) (see page 580) v Fuser rear assembly (with 8-118-14) v v Fuser rear cover v v Exit eliminator v v Eliminator plate L v v Eliminator plate R v Exchange chute Description

Chapter 8. Parts Catalog 565

Table 73. Assembly 8: Fuser and paper exit I (continued)


Asm Index 8 16 17 18 19 20 21 22 23 24 25 26 27 28 B3 B3 C4 C4 B3, B4 B3, B4 B4 B4 B4 C2 C2 B2 A3 NP NP NP NP NP NP NP NP NP NP NP NP NP 1 1 1 1 6 6 6 1 1 1 1 1 1 Grid Part Number Units Fuser and paper exit v Exchange lever v Exchange spring v Exit chute v Finger bracket v Size cam v Heat roll nger v Exit chute roll v Exit torsion spring v Exit actuator v Exit sensor v Exit sensor clip v Clip v Cover Description

Chapter 8. Parts Catalog 566

Assembly 9: Fuser and Paper Exit II


1 2 3 4
1 (with 2-34)

hc2m309F

Chapter 8. Parts Catalog 567

Table 74. Assembly 9: Fuser and Paper Exit II


Asm Index 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 A4 C3 A2 A1 A2 C3 B3 B2 B3 A2 B1, C3 B1 C3 C3 A4 A3, A4 A3, A4 A3 A4 NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1 Grid Part Number Units Fuser and Paper Exit II Fuser sub assembly (with 9-29-34) (same as 8-2) v Fuser frame assembly v Connector bracket1 v Fuser harness v Heater assembly v Lamp guide v Thermal fuse v Thermostat v Temperature sensor assembly v Heat roll v Heat roll ring v Heat roll bearing L v Heat roll bearing R v Heat roll diode v Pressure roll v Pressure roll bearing v Nip spring v Nip lever L v Nip lever R Description

Chapter 8. Parts Catalog 568

Table 74. Assembly 9: Fuser and Paper Exit II (continued)


Asm Index 9 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 C1 B3 C2 C1 C1 B1 B1 B1 B1 B1 B1 C1 B3 B3 B2 NP NP NP NP NP NP NP NP NP NP NP NP NP NP NP 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 Grid Part Number Units Fuser and Paper Exit II v Pressure roll eliminator v Pressure roll earth plate v Fuser inlet chute v Heat roll idler gear v Heat roll idler ange v Heat roll idler shaft v Heat roll gear v Exit idler gear v Exit idler shaft v Exit gear v Exit bearing v Exit roll assembly v STS plate v Pad v Clip Description

Chapter 8. Parts Catalog 569

Assembly 10: Fuser and Drive


1 2 3 4

hc2m310F

Chapter 8. Parts Catalog 570

Table 75. Assembly 10: Fuser and Drive


Asm Index 10 2 4 5 6 7 8 9 10 11 12 C2 A1 A2 A4 A4 A4 A4 A3 C4 C4 NP NP NP 90H3294 90H3295 NP 90H3296 90H3297 NP NP 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Fuser and drive Base frame assembly Right frame assembly Rear tie plate Main motor Paper handling gear assembly Drive bearing L Registration clutch assembly Main gear assembly Left frame sub assembly Frame bottom plate Description

AsmIndex numbers not used: 1, 3

Chapter 8. Parts Catalog 571

Assembly 11: Pop Up and Xerographics


1 2 3 4

20 (with 1-23)
A A

20A
C C

hc2m311F

Chapter 8. Parts Catalog 572

Table 76. Assembly 11: Pop Up and Xerographics


Asm Index 11 20 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 A3 A1 A3 A1 A2 A2 A2 A3 B1 A1 A1 B2 A1, B2 A1, A2 A1, A2 B1 A1, A2 B1, B2 B1 NP 90H3302 NP NP 90H3299 NP 90H3300 90H3301 90H3304 NP NP 90H3298 NP NP 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 2 2 1 Grid Part Number Units Pop Up and Xerographics Pop Up/ROS assembly (with 1111123) v Pop up frame v Pop up shaft v Fuser guide lever v Pop up bearing L v Pop up bearing R v Pop up spring, left (in kit P/N 90H3380) (see page 580) v Pop up spring, right (in kit P/N 90H3380) (see page 580) v Latch lever v Latch shaft v Pop up latch, left v Pop up latch, right v Pop up latch spring (in kit P/N 90H3380) (see page 580) v CRU latch v CRU latch spring (in kit P/N 90H3380) (see page 580) v CRU sensor assembly v ROS spring holder v ROS push spring (in kit P/N 90H3380) (see page 580) v ROS support Description

Chapter 8. Parts Catalog 573

Table 76. Assembly 11: Pop Up and Xerographics (continued)


Asm Index 11 19 20A 21 22 23 24 25 26 30 31 32 33 40 B1 C1 A1 B1, B2 A2 A2 A1 A2 A4 A4 B3 A4 C2 90H3303 NP NP 90H3305 NP NP NP NP 90H3306 90H3307 NP NP 90H0748 1 1 1 2 3 1 1 1 1 1 1 1 1 Grid Part Number Units Pop Up and Xerographics v Interlock actuator v ROS assembly v Guide arm v Pop up latch foot v Pop up clamp Shaft earth wire Pop up earth wire ROS spacer CRU guide assembly, left CRU guide assembly, right Earth plate L Earth spring R EP (Toner) cartridge (Supply Item) Description

AsmIndex numbers not used: 27 to 29, and 34 to 39

Chapter 8. Parts Catalog 574

Assembly 12: Electrical I


1 2 3 4

43

42
hc2m312F

Chapter 8. Parts Catalog 575

Table 77. Assembly 12: Electrical I


Asm Index 12 1 2 3 4 4 5 6 7 8 8 8 9 10 11 12 13 14 15 16 A3 B1 A2 C3 C3 C2 A3 A2 C3 C3 C3 B3 B3 A3 A4 B2 C4 A4 B4 90H3308 90H3309 90H3310 90H3311 90H3312 NP 90H3313 NP 07L0039 90H3314 07L0040 NP NP 90H3315 NP 11L5355 90H3316 90H3317 90H3318 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Electrical I Interlock switch Fuser cover switch Fan Low voltage power supply (100/110V) Low voltage power supply (220V) Inlet holder Duplex interface PWB Fan duct MCU PWB (100V) MCU PWB (110V) MCU PWB (220V) MCU holder HVPS spacer High voltage power supply Knob volume Fuser cover harness LVPS harness HVPS harness ROS harness Description

Chapter 8. Parts Catalog 576

Table 77. Assembly 12: Electrical I (continued)


Asm Index 12 17 18 19 20 21 22 23 40 41 42 43 C4 C4 C2 C2 B4 B1 C4 A1, A2 A1 C4 C3 90H3319 11L5356 NP NP NP NP NP NP NP 11L6587 NP 1 1 1 1 1 1 2 2 1 1 1 Grid Part Number Units Electrical I Tray harness Toner relay harness Power cord Adapter Ferrite core1 Clamp P Clamp F Fan guard Bracket Fan, LVPS (7 Amp LVPS Only) Fan mounting bracket Description

AsmIndex numbers not used: 24 to 39

Chapter 8. Parts Catalog 577

Assembly 13: Electrical II


1 2 3 4
2 9

8 3

5
hc2m313F

Chapter 8. Parts Catalog 578

Table 78. Assembly 13: Electrical II


Asm Index 13 2 3 5 6 7 8 9 A3 B2 C1 B4 C4 B4 A4 90H0703 90H0753 NP 90H0705 07L0041 90H3320 NP 1 1 2 1 1 1 1 Grid Part Number Units Electrical II Cage Bezel Panel cap Controller PWB Controller harness Console harness Panel Description

AsmIndex numbers not used: 1, 4

Chapter 8. Parts Catalog 579

Assembly 99: Kits


Table 79. Assembly 99: Kits
Asm Index 99 06L9997 NP NP NP NP NP 90H3380 NP NP NP NP NP NP NP NP NP NP Part Number Kits Bearing kit v Feed bearing (4-6) v Turn bearing (4-13) v Registration front bearing (7-15) v Registration back bearing (7-16) v Drive left bearing (10-8) Spring kit v Turn chute spring (3-3) v Feed spring (4-7) v MSI normal force spring (5-6) v Pick up spring (6-16) v BTR left spring (7-4) v BTR right spring (7-5) v Full stack spring (8-9) v Pop up spring, left (11-6) v Pop up spring, right (11-7) v Pop up latch (11-12) Description

Chapter 8. Parts Catalog 580

Table 79. Assembly 99: Kits (continued)


Asm Index 99 NP NP 90H3384 NP NP NP NP NP NP NP NP 11L5322 NP NP NP Part Number Kits v CRU latch spring (11-14) v ROS push spring (11-17) Gear kit v Turn gear (4-12) v Turn idler gear (4-14) v Feed idler gear (4-15) v Out idler gear (4-16) v Pick up gear (6-15) v Registration in gear (7-12) v Registration front gear (7-13) v Registration back gear (7-14) Hardware kit v Screw S (machine, collared, 6mm) v Screw X (self-tapping, collared, 8mm) v Screw X (machine, collared, 10mm) v Thumbscrews 11L5321 NP NP Duplex bearing kit v Duplex bearing (31-10) v Duplex bearing (31-13) Description

Chapter 8. Parts Catalog 581

Table 79. Assembly 99: Kits (continued)


Asm Index 99 NP NP 07L0026 NP 06L9998 NP NP NP NP NP NP 90H0781 NP NP NP NP 90H0800 NP NP Part Number Kits v Pulley gear(31-14) v Duplex collar (31-15) Repack/Relocation kit v Box and packing materials Duplex gear kit v One-way gear (31-17) v Duplex gear D (31-18) v Duplex gear C (31-19) v Duplex gear B (31-20) v Duplex gear A (31-21) v Offset gear (31-22) Feed core kit v Feed core (4-3) v Feed core spring (4-4) v Feed gear (4-5) v Feed spring (4-7) Retard pad kit v Retard pad (6-18) v Retard pad spring (6-19) Description

Chapter 8. Parts Catalog 582

Table 79. Assembly 99: Kits (continued)


Asm Index 99 90H3290 NP NP NP NP 90H3478 NP NP NP NP 90H3479 NP NP NP NP NP NP 90H3480 NP Part Number Kits Registration actuator kit v Registration sensor (7-6) v Registration actuator (7-7) v Registration spring (7-8) v Registration sensor bracket (7-9) Rear cover kit v Rear cover (42-2) v Spring (42-4) v Paper chute (42-5) v Strap (42-33) Transport roll kit v Transport roll (42-7) v Right hand lock (42-8) v Left hand lock (42-24) v Spacer (42-35) v E-ring v KL-Clip Feed roller kit v Feed roller (42-14) Description

Chapter 8. Parts Catalog 583

Table 79. Assembly 99: Kits (continued)


Asm Index 99 NP NP NP 11L5352 NP NP Part Number Kits v Feed roller bracket (42-15) v Right hand feed roller bracket (42-16) v Left hand feed roller bracket (42-17) Kit connector kit v Connector harness (42-30) v Screw (42-31) Description

Chapter 8. Parts Catalog 584

Assembly 100: Firmware


Table 80. Assembly 100: Firmware
Asm Index 100 1 2 3 4 5 7 8 9 10 11 12 13 14 15 16 17 18 90H0705 90H0703 90H0753 11L5325 11L5326 11L5327 11L5328 63H2837 63H2834 90H0610 63H2443 63H2444 63H2463 63H2465 63H2467 63H2469 07L0023 Part Number Firmware Controller Cage Bezel PCL/PS SIMM (8MB) IPDS SIMM Twinax card Coax card Ethernet card T/R card Hard drives Macro ash (2MB) Macro ash (4MB) DRAM (4MB) DRAM (8MB) DRAM (16MB) DRAM (32MB) PCL SIMM Simplied Chinese DBCS Description

Chapter 8. Parts Catalog 585

Table 80. Assembly 100: Firmware (continued)


Asm Index 100 19 20 21 22 07L0022 07L0021 11L6581 11L6624 Part Number Firmware PCL SIMM Traditional Chinese DBCS Japanese Heisei Fonts PAGES/ESCP SIMM (8MB) PCL/PS SIMM (8MB) for 4320-003 Description

Chapter 8. Parts Catalog 586

Miscellaneous Items Commonly Used Parts


Description Pick up roll kit MSI (auxiliary tray) retard (separation) pad MCU PWB Fan Fuser assembly, 100 VAC (supply item) Fuser assembly, 110 VAC (supply item) Fuser assembly, 220 VAC (supply item) High-voltage power supply assembly Low-voltage power supply, 100/110 VAC Low-voltage power supply, 220 VAC Controller Part Number 90H0798 90H0800 90H3314 90H3310 90H3465 90H0750 90H0751 90H3315 90H3311 90H3312 90H0705 AsmIndex / Page 6-8 6-18 12-8 12-3 8-1 8-1 8-1 12-8 12-4 12-4 13-6, 100-1 Units 1 1 1 1 1 1 1 1 1 1 1

Chapter 8. Parts Catalog 587

Commonly Used Fasteners


Where Used Fan Internal paper handling Laser/scanner Main motor (MT1) Metal parts Plastic parts Description Screw, M3x30, no washer Screw, M4x10, black-L9, head Screw, M3x20, brass colored M4x8, formed washer M3x6, formed washer M3x6, double washer Part Number

Tools
There are no special tools required to service the IBM InfoPrint 20.

Cleaners and Lubricants


The following cleaners and lubricants are approved for use with this printer:
Item Cleaner Cover cleaner Grease Oil Use Cleaning metal parts Cleaning plastic, rubber, and external parts Lubricating gear teeth Lubricating gear shafts and bearings Part Number 2286522 6933028 1280441 1280443 Remarks Solvent based cleaner Water based, mild detergent General purpose grease, medium weight General purpose oil, medium viscosity

Chapter 8. Parts Catalog 588

Appendix A. Features
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589

Standard Features
v v v v v v v v v v Printing speed of up to 20 pages per minute Resolution of 600 dots per inch (dpi), switchable to 1200 dpi emulation PCL5e support Adobe PostScript 3 4MB of memory Parallel interface (IEEE Std 1284-1994) 500-sheet paper tray 150-sheet auxiliary tray 500-sheet paper output bin Printer drivers

Optional Features
Feature Duplex Unit Paper Drawer/500-Sheet A4/Letter Paper Drawer/500-Sheet A3/Ledger 500-Sheet Tray - A4/Letter Copyright IBM Corp. 1998 Feature Number 4402 4501 4502 4503 Part Number 90H0716 90H0717 90H3341 90H0718

589

Feature 500-Sheet Tray - A3/Ledger 2,000 Sheet Input Drawer Envelope Tray Network Card for Token-Ring Network Card for Ethernet IBM IPDS SIMM IBM Coax SCS Interface IBM Twinax SCS Interface 4MB Memory SIMM 8MB Memory SIMM 16MB Memory SIMM 32MB Memory SIMM 2MB Flash Memory 4MB Flash Memory Hard Drive PC Parallel Cable Software CD Kit Operator Panel Overlays 6 ft US (Chicago) Line Cord Japanese Heisei Font PAGES & ESC/P SIMM

Feature Number 4504 4620 4511 4120 4161 4820 4171 4141 4304 4308 4316 4332 4030 4032 4320

Part Number 90H0719 90H0720 90H0721 06L9835 06L9838 90H0746 06L9846 06L9849 63H2463 63H2465 63H2467 63H2469 63H2443 63H2444 90H0610 63H1956 90H0749 90H3335 6952301

4810 4840

07L0012 11L6578

Appendix A. Features 590

Appendix B. Supplies
Ordering Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592

Ordering Supplies
In the U.S.A. or Canada, order printing supplies from IBM Printer Supplies, 1-888-IBM PRINT (1-888-426-7746). In v v v v v v v v Europe, call IBM Supplies Fulllment Operations at 31-43-3502756, or at one of the following numbers: Denmark: 80015534 Finland: 08001-13110 France: 05-905871 Germany: 0130 818005 Italy: 1-678 78349 Norway: 800-11389 Sweden: 020-794270 United Kingdom: 0800-968679

Copyright IBM Corp. 1998

591

Part Numbers
The customer is responsible for buying and replacing the following supplies.
Supply EP (Toner) Cartridge Usage Kit (100 Volt) Usage Kit (110 Volt) Usage Kit (230 Volt) Average Yield 14,000 impressions 200,000 impressions 200,000 impressions 200,000 impressions Part Number 90H0748 90H3465 90H0750 90H0751

Notes: 1. For the EP (Toner) cartridge and usage kits, the approximate average yield has been established with a coverage of 5 percent. An impression is dened as one side of a printed letter-size page with a 1/2 border around the page. A duplex page is dened as two impressions. A toner cartridge can print approximately 14,000 pages of Letter-size paper, containing text or graphics that cover 5% of the page. Depending on the type of printing you do, you can obtain up to double the page yield if you use the ECONO setting for the QUALITY item on the Cong Menu or if you select toner saver print quality mode from your printer driver. (Note that the driver setting will override the menu setting.) For example, using ECONO and a density setting of 1, you may be able to print up to 28,000 images at 5% coverage. Note: The actual page yield is affected by the environment, the type of print media, the percentage of text and graphics, the complexity of the graphics, and other factors. 2. The usage kit includes a fuser assembly and transfer charging (BTR) roller assembly.

Appendix B. Supplies 592

Appendix C. Media Specications


Attention: Please use print materials that conform to the specications listed in the following sections. Using non-conforming print materials can decrease page yield, cause jams, and damage your printer. The following sections contain information about selecting print materials, including: v Auxiliary Tray Paper Specications on page 595 v A4/Letter Tray Paper Specications on page 598 v A3/Ledger (11 inches x 17 inches) Tray Paper Specications on page 599 v Envelope Tray Paper Specications on page 601 v 2000-Sheet Input Drawer Paper Specications on page 601 Notes: 1. The following media weights are supported: v Paper trays: 16-28 pound (60-105 grams/meter) v Envelope tray: 16-28 pound (60-105 grams/meter) v Auxiliary tray: Paper, labels, transparencies, envelopes: 60-135 grams/meter Japanese Official Postcard: 190 grams/meter v 2000-Sheet Input Drawer: 16-28 pound paper (60-105 grams/meter) 2. Do not use the following types of paper and printable material in your printer: v Multipart forms v Stapled, folded, or wrinkled paper v Smooth or coated paper
Copyright IBM Corp. 1998

593

3. Use the auxiliary tray to print transparencies or labels. Do not feed these types of print media from the paper trays. 4. Some recycled papers release paper dust that can accumulate and cause frequent paper jams and reduced supplies life. 5. High humidity can damage paper. Try to store paper where it is cool and dry.

Appendix C. Media Specications 594

Auxiliary Tray Paper Specications


Style Size Paper Letter 8.5 x 11 in 215.9 x 279.4 mm Legal 8.5 x 14 in 215.9 x 355.6 mm Folio 8.5 x 13 in 215.9 x 330.2 mm 11 x 17 11 x 17 in 279.4 x 431.8 mm A4 8.27 x 11.69 in 210 x 297 mm B5-JIS 7.16 x 10.12 in 182 x 257 mm B4 10.12 x 14.33 in 257 x 364 mm A5 5.85 x 8.27 in 148.5 x 210 mm No No Yes Yes Yes No No Yes Yes Yes Yes Yes Yes Yes No Yes Yes No Yes Yes No Yes Yes Yes Duplex Short-edge feed Long-edge feed (SEF) (LEF)

Appendix C. Media Specications

595

Style A3

Size Yes 11.69 x 16.54 in 297 x 420 mm

Duplex

Short-edge feed Long-edge feed (SEF) (LEF) Yes No

Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm Custom forms Minimum: 3.5 x 5.8 in 88 x 148 mm Maximum: 13 x 20 in 330 x 508 mm

No

No

Yes

No

No

Yes

No

Yes

No

Envelopes and Postcards Japanese Official Postcard (Hagaki) 3.94 x 5.83 in 100 x 148 mm Monarch 3.875 x 7.5 in 98.4 x 190.5 mm COM10 4.125 x 9.5 in 104.8 x 241.3 mm No Yes No No Yes No No Yes No

Appendix C. Media Specications

596

Style C5

Size No 6.38 x 11.77 in 162 x 229 mm

Duplex

Short-edge feed Long-edge feed (SEF) (LEF) Yes No

DL 4.33 x 8.66 in 110 x 220 mm Custom envelopes Minimum: 3.5 x 5.8 in 88 x 148 mm Maximum: 13 x 20 in 330 x 508 mm

No

Yes

No

No

Yes

No

Appendix C. Media Specications

597

A4/Letter Tray Paper Specications


LTR Paper Group Style Letter 8.5 x 11 in 215.9 x 279.4 mm A4 8.27 x 11.69 in 210 x 297 mm B5-JIS 7.16 x 10.12 in 182 x 257 mm Not supported No No Yes Yes No Yes Yes Yes Yes Size Duplex Yes SEF Yes LEF Yes A4 Paper Group Duplex Yes No SEF LEF Yes

A5 5.85 x 8.27 in 148.5 x 210 mm

Not supported

No

No

Yes

Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm

No

No

Yes

Not supported

No

No

Yes

Not supported

Appendix C. Media Specications 598

A3/Ledger (11 inches x 17 inches) Tray Paper Specications


LTR Paper Group Style Letter 8.5 x 11 in 215.9 x 279.4 mm Legal 8.5 x 14 in 215.9 x 355.6 mm Folio 8.5 x 13 in 215.9 x 330.2 mm 11 x 17 11 x 17 in 279.4 x 431.8 mm A4 8.27 x 11.69 in 210 x 297 mm B5-JIS 7.16 x 10.12 in 182 x 257 mm Not supported No No Yes Yes No Yes Yes Yes Yes Yes Yes No Yes Yes No Yes Yes No Yes Yes No Yes Yes No Yes Yes No Size Duplex Yes SEF Yes LEF Yes A4 Paper Group Duplex Yes No SEF LEF Yes

B4 10.12 x 14.33 in 257 x 364 mm

Yes

Yes

No

Yes

Yes

No

Appendix C. Media Specications 599

LTR Paper Group Style A5 5.85 x 8.27 in 148.5 x 210 mm Size Duplex Not supported SEF LEF No

A4 Paper Group Duplex No SEF LEF Yes

A3 11.69 x 16.54 in 297 x 420 mm Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm

Yes

Yes

No

Yes

Yes

No

No

No

Yes

Not supported

No

No

Yes

Not supported

Appendix C. Media Specications 600

Envelope Tray Paper Specications


Style Monarch 3.875 x 7.5 in 98.4 x 190.5 mm COM10 4.125 x 9.5 in 104.8 x 241.3 mm C5 6.38 x 11.77 in 162 x 229 mm DL 4.33 x 8.66 in 110 x 220 mm No Yes No No Yes No No Yes No Size No Duplex Short-edge feed Long-edge feed (SEF) (LEF) Yes No

2000-Sheet Input Drawer Paper Specications


Style Letter 8.5 x 11 in 215.9 x 279.4 mm A4 8.27 x 11.69 in 210 x 297 mm Yes No Yes Size Yes Duplex Short-edge feed Long-edge feed (SEF) (LEF) No Yes

Appendix C. Media Specications

601

Appendix D. Technical Support


IBM Warranty Information . . . . . . . . . . . . . . . . . . . . . . . Technical Support Numbers . . . . . . . . . . . . . . . . . . . . . . Obtaining Documents, Drivers, and Utilities from the World Wide Web Obtaining Code Updates from the World Wide Web. . . . . . . . . . Dealer Warranty Claim Center (DWCC)U.S.A. only . . . . . . . . . Printer Sales Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602 .602 .603 .603 .603 .603

IBM Warranty Information


Warranty period: 12 months Warranty offerings: On-site: v Dealer v IBM service

Technical Support Numbers


IBM customer support for this printer is available at no charge when covered by an IBM maintenance agreement or the IBM one-year warranty period. If the printer requires repair, the support representative will explain the customers options. v U.S.A. and Canada: 1-800-358-6661. v Outside the U.S.A. and Canada, customers should call their country customer service center numbers.

Copyright IBM Corp. 1998

602

Obtaining Documents, Drivers, and Utilities from the World Wide Web
To obtain current versions of the InfoPrint 20 documentation, printer drivers, utilities, and programs, the customer can do the following: 1. Access the IBM Printing Systems Company home page:
http://www.printers.ibm.com

2. Navigate to the document, printer driver, utility, or program needed and follow the instructions to download it.

Obtaining Code Updates from the World Wide Web


To obtain code updates for the InfoPrint 20, if required, the customer can do the following: 1. Access the IBM Printing Systems Company home page:
http://www.printers.ibm.com

2. Navigate to the code update needed and follow the instructions to download it.

Dealer Warranty Claim Center (DWCC)U.S.A. only


To order warranty parts and request warranty claim reimbursements through the Dealer Warranty Claims Center, call: 1-800-388-7080

Printer Sales Information


IBM Printer Remarketer: 1-800-793-5888 (U.S.A.) or IBM country remarketer.

Appendix D. Technical Support 603

Appendix E. Duplex Unit Option


Diagnostics . . . . . . . . . . . . . . . . 09 DUPLEX COVER OPEN . . . . . . . 22 PAPER JAM (or 21 PAPER JAM from 29 OUTPUT FULL, with Duplex Installed Wiring Diagram . . . . . . . . . . . . . . Removal Procedures, Adjustments . . . . Duplex Unit . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Duplex Left Cover . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Duplex Right Cover . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Duplex Upper Cover . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Duplex Lower Cover . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Offset Motor . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Duplex PWB . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . .
Copyright IBM Corp. 1998

. . . . . . . . . . Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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.607 .607 .608 .610 .614 .615 .615 .616 .616 .617 .618 .618 .619 .619 .620 .621 .622 .622 .623 .623 .624 .625 .626 .626 .627 .627 .628 604

Duplex Cover Switch1 . Removal . . . . . . . Replacement. . . . . Duplex Cover Switch2 . Removal . . . . . . . Replacement. . . . . Duplex Pass Sensor . . Removal . . . . . . . Replacement. . . . . Duplex Stack Sensor . Removal . . . . . . . Replacement. . . . . Duplex Stack Actuator . Removal . . . . . . . Replacement. . . . . Offset Guide Arm . . . Removal . . . . . . . Replacement. . . . . Offset Assembly . . . . Removal . . . . . . . Replacement. . . . . Duplex Upper Roll . . . Removal . . . . . . . Replacement. . . . . Duplex Lower Roll . . . Removal . . . . . . . Replacement. . . . . Duplex Motor . . . . . Removal . . . . . . . Replacement. . . . .

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.629 .629 .630 .631 .631 .632 .633 .633 .634 .635 .635 .636 .637 .637 .638 .639 .640 .640 .641 .641 .643 .645 .645 .646 .648 .648 .649 .650 .651 .651

Appendix E. Duplex Unit Option 605

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652 Assembly 30: Duplex Unit and Offset Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652 Assembly 31: Duplex Unit and Offset Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655

Appendix E. Duplex Unit Option 606

Diagnostics
If the problem involves only duplex printing, install a new duplex unit.

09 DUPLEX COVER OPEN


One of the duplex covers is open. Ensure that both covers are closed correctly. Also ensure that the option is installed correctly and plugged tightly to the connector on the Duplex Interface PWB.
Table 81. 09 DUPLEX COVER OPEN
Step Actions and Questions SUSPECT COMPONENTS v Duplex Option (Asm-Index: 30-1, page 652) v Duplex Interface PWB (Asm-Index: 12-6, page 575) v MCU Yes No

Appendix E. Duplex Unit Option 607

22 PAPER JAM (or 21 PAPER JAM from Duplex)


There was a paper jam at the duplex option.
Table 82. 22 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Duplex Option (Asm-Index: 30-1, page 652) DUPLEX OPTION 1. Check for dirty rolls, obstructions, broken actuators, etc. Is the problem xed? DUPLEX OPTION Install a new Duplex Option (see page Duplex Unit on page 615). Note: The following diagnostics are available: 2. v Sensors D21 SENSOR TEST on page 261 v Duplex Motor D63 MOTOR D CW (Duplex Motor Runs CW) on page 287 and D64 MOTOR D CCW (Duplex Motor Runs CCW) on page 289 Is the problem xed? Verify the x. Also Go to Skewed verify that the Image on problem job prints. page 212 Verify the x. Also Go to step 2 verify that the problem job prints. Yes No

Appendix E. Duplex Unit Option 608

Table 82. 22 PAPER JAM (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

3.

Appendix E. Duplex Unit Option 609

29 OUTPUT FULL, with Duplex Installed


Without a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index: 8-8, page 564) within the Fuser Assembly. When a duplex option is installed, the printer monitors the Duplex Stack Actuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator. When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed on the operator panel. The printer will continue to print a few more pages to clear the paper path before it stops. The 29 OUTPUT FULL message remains until the signals indicate that the the paper stack has been removed. Notes: 1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printer will stop after the paper path clears. 2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the customer can probably remove the duplex unit and continue to print simplex jobs.
Table 83. 29 OUTPUT FULL, with Duplex Installed
Step Actions and Questions SUSPECT COMPONENTS v Duplex Full Stack Actuator (Asm-Index: 30-18, page 652) v Duplex Unit (Asm-Index: 30-1, page 652) v Duplex Interface PWB (Asm-Index: 12-6, page 575) v MCU PWB (Asm-Index: 12-8, page 575) Yes No

Appendix E. Duplex Unit Option 610

Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)


Step Actions and Questions SENSOR TEST a. Use D21 SENSOR TEST on page 261 to check the Duplex Full Stack Actuator and Sensor. b. Press and release the actuator. Is the sensor OK? DUPLEX STACK ACTUATOR a. Unplug the duplex option from the back of the printer. b. Carefully remove the option from the printer. c. Place the option on a table. d. Manually actuate the Duplex Stack Acutator and observe the Duplex Stack Sensor at the other end of the actuator. Look for debris that could obstruct the actuator or sensor. Are the actuator and sensor OK? DUPLEX UNIT INSTALLATION a. Carefully install the duplex option on the printer. Tighten the thumbscrews. b. Plug the duplex option into the printer connection and tighten the thumbscrews. c. Run TEST MENU/CONTINUOUS TEST for about 10 pages. Then press the CANCEL key (the printer will print many more pages before stopping). Does the 29 OUTPUT FULL message display? Go to Step 4 Problem appears xed. Verify the x. Also verify that the problem job prints. Go to step 3 Repair as needed or install a new Duplex Unit. Yes Possible intermittent or MCU problem No Go to step 2

1.

2.

3.

Appendix E. Duplex Unit Option 611

Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)


Step Actions and Questions Yes No Go to Step 5

4.

DUPLEX UNIT The original duplex unit was a. Install a new (or borrowed) duplex unit. Note: The printer can probably continue to be used without the duplex bad. unit if a new duplex unit is needed but not immediately available. b. Repeat the D21 test Is the sensor OK? FULL STACK SENSING WITHOUT THE DUPLEX UNIT Go to Step 6 a. Remove the duplex unit. b. Repeat D21, activating the base Full Stack Actuator (at the fuser asm).

5.

Is the sensor OK?

The only component shared by the Full Stack sensor and the Duplex Full Stack Sensor circuits is the MCU. Install a new MCU.

Install a new Duplex Interface PWB (See page 615). Ensure that the connection at the MCU is completely seated- it can look connected when it is not. 6. Is the problem xed?

Verify the x. Also Install a new MCU verify that the problem job prints.

Appendix E. Duplex Unit Option

612

Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)


Step Actions and Questions End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602). Yes No

7.

Appendix E. Duplex Unit Option 613

Wiring Diagram
OFFSET MOTOR
M
P/J196

DUPLEX MOTOR
M
P/J197

DUPLEX PASS SENSOR

P/J195

DUP STACK SENSOR

P/J 192

P/J186

P/J187

DUP COVER SWITCH 1

P/J 193

P/J 184

DUPLEX PWB

DUP COVER SWITCH 2

P183
P/J 198

MCU
P182

DUPLEX INTERFACE PWB

P/J 18

P/J 20

HC2M815F

Appendix E. Duplex Unit Option 614

Removal Procedures, Adjustments Duplex Unit


Asm-Index: 30-1, page 652.
1 2

3
J182
hc2m758F

Figure 82. Duplex Unit Removal

Appendix E. Duplex Unit Option 615

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Disconnect J182 of the duplex cable (Asm-Index: 30-23, page 652) from the rear of the base engine. 3. Remove the paper weight (1) (Asm-Index: 30-30, page 652) from the duplex front cover (2) (Asm-Index: 30-7, page 652). 4. Loosen the two knurled screws (3) on the back side of the duplex unit. 5. Lift the duplex unit up back and remove it from the base engine. 6. Lay the duplex unit on a at surface holding inside up.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 616

Duplex Left Cover


Asm-Index: 30-3, page 652.
4 5 2 1

3 3

J182
hc2m759F

Figure 83. Duplex Left Cover Removal

Appendix E. Duplex Unit Option 617

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. 4. 5. 6. Remove the E-ring (1) holding the left side knurled screw (2). Loosen (do not remove) the two screws (3) securing the duplex left cover (4). Place the duplex unit on a at surface left side up. Tilt the duplex left cover backward and loosen the hook (5) of the left cover from the frame of the duplex unit. 7. Remove the cable from the slot in the left end cover. 8. Lift the left cover and remove it from the duplex unit. 9. Lay the duplex unit on a at surface inner side up.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 618

Duplex Right Cover


Asm-Index: 30-4, page 652.

5 4 2

3 1

hc2m760F

Figure 84. Duplex Right Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615).

Appendix E. Duplex Unit Option 619

3. 4. 5. 6.

Remove the E-ring (1) holding the right side knurled screw (2). Loosen (do not remove) the two screws (3) securing the duplex right cover (4). Place the duplex unit right side up. Open the duplex lower cover (Asm-Index: 30-6, page 652).

7. Tilt the duplex right cover backward and loosen the hook (5) of the right cover from the frame of the duplex unit. 8. Lift the right cover and remove it from the duplex unit. 9. Close the lower cover. 10. Lay the duplex unit on a at surface inside up.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 620

Duplex Upper Cover


Asm-Index: 30-5, page 652.

2 1

hc2m761

Figure 85. Duplex Upper Cover Removal

Appendix E. Duplex Unit Option 621

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Hold the duplex upper cover (1) half open. 3. Remove the duplex straps (2) (Asm-Index: 30-22, page 652) from the duplex unit (Asm-Index: 30-1, page 652). 4. Slide the upper cover to the left up, and release the right side hinge boss from the frame of the duplex unit pressing the arm inside using a at blade screwdriver, if necessary. 5. Remove the left side hinge boss from the frame.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 622

Duplex Lower Cover


Asm-Index: 30-6, page 652.

1
hc2m762F

Figure 86. Duplex Lower Cover Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Hold the duplex lower cover (1) half open. 3. Slide the lower cover to the left up, then remove the right side hinge boss from the frame of the duplex unit (Asm-Index: 30-1, page 652) pressing the arm inside using a at blade screwdriver, if necessary.

Appendix E. Duplex Unit Option 623

4. Remove the left side hinge boss from the frame.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 624

Offset Motor
Asm-Index: 30-21, page 652.

hc2m764F

2
J186

Figure 87. Offset Motor Removal

Appendix E. Duplex Unit Option 625

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Disconnect the J186 of the offset motor (1) (Asm-Index: 30-21, page 652) from the duplex PWB (Asm-Index: 30-10, page 652). 5. Place the duplex unit left side up. 6. Remove the two screws (2) securing the offset motor. 7. Remove the motor from the frame of the duplex unit tilting the motor slightly to the right so that the lever leaves the offset guide arm (Asm-Index: 30-20, page 652).

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 626

Duplex PWB
Asm-Index: 30-10, page 652.

J182

2 2
J183

J187 J184

1 2

hc2m765F

Figure 88. Duplex PWB Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617).
Appendix E. Duplex Unit Option 627

4. Remove the offset motor (See page 625). 5. Disconnect P/Js below from the duplex PWB (1). v J183 of the duplex sensor harness (Asm-Index: 30-15, page 652) v J184 of the duplex sensor harness (Asm-Index: 30-15, page 652) v J187 of the duplex motor harness (Asm-Index: 30-14, page 652) 6. Remove the four screws (2) securing the duplex PWB and remove it from the frame of the duplex unit.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 628

Duplex Cover Switch1


Asm-Index: 30-11, page 652.

J193

hc2m766F

Figure 89. Duplex Cover Switch1 Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the duplex upper cover (Asm-Index: 30-5, page 652).
Appendix E. Duplex Unit Option 629

3. Nip the duplex cover switch 1 (1) in a vertical direction and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652). Attention: Be careful not to damage the duplex sensor harness (Asm-Index: 30-15, page 652). 4. Disconnect J193 of the duplex sensor harness from the switch.

Replacement
1. 2. 3. 4. 5. Open the duplex upper cover. Reconnect J193 of the duplex sensor harness to the duplex cover switch1. Push the switch into the opening in the frame until the switch snaps in place. Route the wires of the harness inside the frame of the duplex unit. Close the duplex upper cover. Note: Ensure that the tab on the duplex upper cover presses the switch.

Appendix E. Duplex Unit Option 630

Duplex Cover Switch2


Asm-Index: 30-12, page 652.

J198

1
hc2m767F

Figure 90. Duplex Cover Switch2 Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Disconnect J198 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex cover switch 2 (1). 4. Remove the duplex lower cover (See page 623).

Appendix E. Duplex Unit Option 631

5. Nip the duplex cover switch2 in a vertical direction from the back side of the duplex unit (Asm-Index: 30-1, page 652), using a needle nosed pliers if necessary, and pull the switch out from the frame of the duplex unit.

Replacement
1. 2. 3. 4. 5. Lay the duplex unit back side up. Push the duplex switch2 into the opening in the frame of the duplex unit until the switch snaps in place. Reconnect J198 of the duplex sensor harness to the switch. Route the wires of the harness inside of the frame of the duplex unit. Reinstall the duplex lower cover (See page 623).

6. Close the duplex lower cover (Asm-Index: 30-6, page 652). Note: Ensure that the tab of the duplex lower cover presses the duplex cover switch2. 7. Reinstall the duplex unit (See page 615).

Appendix E. Duplex Unit Option 632

Duplex Pass Sensor


Asm-Index: 30-13, page 652.
J195

hc2m768F

Figure 91. Duplex Pass Sensor Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Disconnect J195 from the duplex pass sensor (1). 4. Nip the hooks of the sensor and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652).

Appendix E. Duplex Unit Option 633

Replacement
1. Lay the duplex unit inside up. 2. Push the duplex pass sensor into the hole in the frame until the sensor snaps in place. 3. Reconnect J195 to the sensor. Note: Ensure that the harness wires are in the hanger. 4. Reinstall the duplex unit (See page 615).

Appendix E. Duplex Unit Option 634

Duplex Stack Sensor


Asm-Index: 30-17, page 652.
1
J192

hc2m769F

Figure 92. Duplex Stack Sensor Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621). 3. Remove the duplex unit (See page 615). 4. Remove the duplex left cover (See page 617). 5. Remove the duplex right cover (See page 619). 6. Remove the duplex front cover. 7. Lay the duplex unit (Asm-Index: 30-1, page 652) inside up on a pillow so that the actuator of the duplex pass sensor (Asm-Index: 30-13, page 652) does not touch the oor.

Appendix E. Duplex Unit Option 635

8. Disconnect J192 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex stack sensor (1). 9. Nip the hooks of the stack sensor and remove it from the duplex eliminator assembly (Asm-Index: 30-16, page 652).

Replacement
1. Lay the duplex unit inside up on a pillow so that the actuator of the duplex pass sensor does not touch the oor. 2. Push the duplex stack sensor into the opening until the sensor snaps in place. 3. Reconnect J192 of the duplex sensor harness to the sensor. 4. Route the wires of harness into the frame of the duplex unit. 5. Reinstall the duplex front cover. 6. Reinstall the duplex right cover (See page 619). 7. Reinstall the duplex left cover (See page 617). 8. Reinstall the duplex unit (See page 615). 9. Reinstall the duplex upper cover (See page 621).

Appendix E. Duplex Unit Option 636

Duplex Stack Actuator


Asm-Index: 30-18, page 652.
1

hc2m770F

Figure 93. Duplex Stack Actuator Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove duplex unit (See page 615). 3. Lay the duplex unit inside up. 4. Nip the center of the bar of the duplex stack actuator (1) using a needle nosed pliers and pull the bar to ex it. 5. Remove the right end of the bar (opposite side of the duplex stack sensor) (Asm-Index: 30-17, page 652) from the hole on the frame of the duplex eliminator assembly (Asm-Index: 30-16, page 652).

Appendix E. Duplex Unit Option 637

6. Turn the lever of the actuator up so that the shielding ag of the actuator leaves from the stack sensor. 7. Slide the actuator to the right and remove the bar from the hole of the duplex eliminator.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 638

Offset Guide Arm


Asm-Index: 30-20, page 652.

hc2m772F

Figure 94. Offset Guide Arm Removal


Note: This procedure is applicable only to the models with the offset Function.

Appendix E. Duplex Unit Option 639

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621). 3. Remove duplex unit (See page 615). 4. Remove duplex left cover (See page 617). 5. Lay the duplex unit inside up on a pillow so that the duplex pass sensor (Asm-Index: 30-13, page 652) does not touch the oor. 6. Tilt the lever of the offset motor (Asm-Index: 30-21, page 652) toward the outside of the duplex unit. 7. Remove the screw (1) securing the offset guide arm (2). 8. Slide the offset guide arm slightly toward the front so that it leaves the lever of the offset motor and remove the arm from the frame.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 640

Offset Assembly
Asm-Index: 31-6, page 655.
1

2 1

hc2m773F

Figure 95. Offset Assembly Removal (1)

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621).

Appendix E. Duplex Unit Option 641

3. Remove the duplex unit (See page 615). 4. Remove the duplex left cover (See page 617). 5. Remove the duplex right cover (See page 619). Note: Step 6 is applicable only to the models without the offset function. 6. Remove the offset hold arm. Note: Step 7 is applicable only to the models with the offset function. 7. Remove the offset guide arm (See page 639). 8. Lay the duplex unit top side down. 9. Remove the two screws (1) securing the duplex support assembly (2) (Asm-Index: 31-4, page 655). 10. Remove the duplex support assembly together with the duplex guide (Asm-Index: 30-8, page 652). 11. Slide the offset assembly (3) right and left and remove the four bearings (4) from the frame of the duplex unit. 12. Lift the right end of the offset assembly in the direction of the cutout in the frame and release the two shafts from the frame of the duplex unit. 13. Slide the offset assembly to the right and remove it with the four duplex bearings (Asm-Index: 31-10, page 655) and two offset gears (5) (Asm-Index: 31-22, page 655) from the frame.

Appendix E. Duplex Unit Option 642

3 4

hc2m774F

Figure 96. Offset Assembly Removal (2)

Replacement
1. 2. 3. 4. Lay the duplex unit top side down. Turn the duplex stack actuator so that the tip of the lever directs to the top of the duplex unit. Hold the shafts of the offset assembly with the gear side to the right. Set two duplex bearings and the offset gear to each shaft in the order below from left side of the shaft. v duplex bearing - (collar right) v duplex bearing - (collar left) v offset gear - (collar left) 5. Insert the left ends of the shafts of the offset assembly into the openings in the frame of the duplex unit. 6. Insert the right side of the shafts of the offset assembly placing the four bearings inside and two gears outside of the frame making sure that the gear collars are on the inside of the large gear (See Figure 99 on page 650).

Appendix E. Duplex Unit Option 643

7. Slide the body of the left side bearings and insert them into the openings in the frame until the collars touch the frame. 8. Place the left side of the duplex support assembly so that its left end xes the left side bearings. 9. Slide the body of the right side bearings and insert them into the openings in the frame until the collars touch the frame. 10. Place the right side of the duplex support assembly. 11. Secure the duplex support assembly using two screws (silver, 6mm). Note: Step 12 is applicable only to the models without the offset function. 12. Reinstall the offset hold arm. Note: Step 13 is applicable only to the models with the offset function. 13. Reinstall the offset guide arm (See page 639). 14. Reinstall the duplex right cover (See page 619). 15. Reinstall the duplex left cover (See page 617). 16. Reinstall the duplex chute (See page 615). 17. Reinstall the duplex upper cover (See page 621).

Appendix E. Duplex Unit Option 644

Duplex Upper Roll


Asm-Index: 31-11, page 655.

J195
hc2m775F

Figure 97. Duplex Upper Roll Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Remove the duplex right cover (See page 619). 5. Lay the duplex unit inside up. 6. Disconnect P/J195 from the duplex pass sensor (Asm-Index: 30-13, page 652). 7. Release the harness from the harness collar (Asm-Index: 31-24, page 655).
Appendix E. Duplex Unit Option 645

8. Remove the harness collar from the duplex upper roll. 9. Remove the left side clamp securing the duplex upper roll. 10. Remove the synchronize belt (Asm-Index: 31-16, page 655). 11. Remove the left side duplex collar (Asm-Index: 31-15, page 655). 12. Remove the pulley gear (Asm-Index: 31-14, page 655). 13. Remove the duplex gear D (Asm-Index: 31-18, page 655). 14. Remove the right side duplex collar and the duplex bearing (Asm-Index: 31-13, page 655). 15. Slide the duplex upper roll to the right and release the right side duplex bearing from the frame of the duplex unit. 16. Lift the right end of the duplex upper roll and remove its right end from the frame. 17. Slide the upper roll to the right and pull out its left end from the frame. 18. Release the hooks and the E-clip of the one way gear (Asm-Index: 31-17, page 655) using a small at blade screwdriver and remove the gear and the bearing from the shaft.

Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. Lay the duplex unit inside up. Hold the shaft of the duplex upper roll with the gear side left. Insert the left end of the shaft of the upper roll into the opening in the frame of the duplex unit. Place right end of the shaft of the upper roll into the cutout in the frame. Place the duplex bearing (collar right) to the shaft from the outside of the frame. Insert the body of the right side duplex bearing into the opening of the frame. Place the one way gear from the right side end of the duplex upper roll until the gear snaps into place. Slide the upper roll to the left. Place the duplex bearing, the duplex collars and the pulley gear on the shaft of the upper roll from the left side of the frame, in the order below.

Appendix E. Duplex Unit Option 646

10. 11. 12. 13. 14. 15.

v duplex bearing (collar left) v duplex collar v pulley gear v duplex collar Secure the collars, etc. to the upper roll using a clamp. Reinstall the synchronize belt. Reinstall the harness collar to the duplex upper roll. Hook the harness of the duplex pass sensor to the harness collar. Reconnect P/J195 to the duplex pass sensor. Reinstall the duplex right cover (See page 619).

16. Reinstall the duplex left cover (See page 617).

Appendix E. Duplex Unit Option 647

Duplex Lower Roll


Asm-Index: 31-12, page 655.

hc2m776F

Figure 98. Duplex Lower Roll Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Remove the duplex right cover (See page 619). 5. Lay the duplex unit inside up. 6. Remove the left side clamp securing the duplex lower roll.
Appendix E. Duplex Unit Option 648

7. Remove the synchronize belt (Asm-Index: 31-16, page 655). 8. Remove the left side duplex collar (Asm-Index: 31-15, page 655), the pulley gear (Asm-Index: 31-14, page 655), and the right side duplex bearing (Asm-Index: 31-13, page 655). 9. 10. 11. 12. 1. 2. 3. 4. 5. 6. 7. Slide the duplex lower roll to the right and release the right side duplex bearing from the frame. Lift the right end of the lower roll and remove its right end from the frame. Slide the lower roll to the right and pull out its left end from the frame. Release the E-ring and remove the duplex bearing from the right end of the shaft.

Replacement
Lay the duplex unit inside up. Hold the shaft of the duplex lower roll with the pulley gear side left. Insert the left end of the shaft of the lower roll into the opening in the frame of the duplex unit. Insert the duplex bearing (collar right) to the shaft of the lower roll from the right end. Secure the bearing using an E-ring. Place the right end of the shaft of the lower roll placing the duplex bearing outside of the frame. Place the left side duplex bearing, the duplex collars and the pulley gear on the lower roll from the outside of the frame, in the order below. v duplex bearing (collar left) v duplex collar v pulley gear v duplex collar 8. Secure the duplex collar, etc. to the lower roll using a clamp. 9. Reinstall the synchronize belt. 10. Reinstall the duplex right cover (See page 619). 11. Reinstall the duplex left cover (See page 617).

Appendix E. Duplex Unit Option 649

Duplex Motor
Asm-Index: 31-23, page 655.

2 1

2 J197
hc2m777F

Figure 99. Duplex Motor Removal

Appendix E. Duplex Unit Option 650

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex right cover (See page 619). 4. Lay the duplex unit inner side up. 5. Disconnect J197 of the duplex motor harness (Asm-Index: 30-14, page 652) from the duplex motor (1). 6. Remove the two screws (2) securing the motor. 7. Remove the duplex motor.

Replacement
Reverse the Removal procedure.

Appendix E. Duplex Unit Option 651

Parts Catalog Assembly 30: Duplex Unit and Offset Feeder I


1 2 3 4

hc2m755F

Appendix E. Duplex Unit Option 652

Table 84. Assembly 30: Duplex Unit and Offset Feeder I


Asm Index 30 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 A4 B3 A1 B4 A4 C3 A2 C2, C3 C3 B1 B2 C2 C2 C1 B1 B2 B2 B2 B1 90H0716 90H0716 90H3359 90H3360 90H3361 90H3362 NP NP NP 90H3363 90H3364 90H3365 90H3366 90H3367 90H3368 NP 63H3079 90H3370 NP 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 Grid Part Number Units Duplex unit and offset feeder I Duplex unit (with 30-230-30) v Duplex paper handling assembly (same as 31-1) v Duplex left cover v Duplex right cover v Duplex upper cover v Duplex lower cover v Duplex front cover v Duplex guide v Duplex gate spring v Duplex PWB v Duplex cover switch 1 v Duplex cover switch 2 v Duplex pass sensor v Duplex motor harness v Duplex sensor harness v Duplex eliminator assembly v Duplex stack sensor v Duplex stack actuator v Offset hold arm Description

Appendix E. Duplex Unit Option 653

Table 84. Assembly 30: Duplex Unit and Offset Feeder I (continued)
Asm Index 30 20 21 22 23 30 B1 B1 A3 C1 A2 90H3371 90H3372 90H3373 90H3374 90H3375 1 1 1 1 1 Grid Part Number Units Duplex unit and offset feeder I v Offset guide arm v Offset motor v Duplex strap v Duplex cable v Paper weight Description

AsmIndex numbers not used: 24 to 29

Appendix E. Duplex Unit Option 654

Assembly 31: Duplex Unit and Offset Feeder II


1 2 3 4

2
C

25 25 25
hc2m756F

Appendix E. Duplex Unit Option 655

Table 85. Assembly 31: Duplex Unit and Offset Feeder II


Asm Index 31 1 2 3 4 5 6 7 8 9 10 11 12 13 A3 C2 C3 B2 B3 A2 A3 A2 A2 A2, A3 C2 C2 A1, A2, A3, B1, C1, C4 B1, B2 B1, C1 B1 C4 C4 90H3378 90H3377 07L0043 8 90H0716 NP NP NP NP 90H3376 1 1 1 1 1 1 1 1 1 4 1 Grid Part Number Units Duplex unit and offset feeder II Duplex paper handling assembly (with 31-2 31-24 (same as 30-2) v Duplex frame L v Duplex frame R v Duplex support assembly v Duplex chute v Offset assembly (with 31-731-10) v Offset chute assembly v Offset roll v v Offset/Exit roll v v Duplex bearing (in kit P/N 11L5321) (see page 580) v v Duplex upper roll v v Duplex lower roll v Duplex bearing (in kit P/N 11L5321) (see page 580) Description

14 15 16 17 18

2 2 1 1 1

v Pulley gear (in kit P/N 11L5321) (see page 580) v Duplex gear (in kit P/N 11L5321) (see page 580) v Sync belt v One-way gear (in kit P/N 06L9998) (see page 580) v Duplex gear D (in kit P/N 06L9998) (see page 580)

Appendix E. Duplex Unit Option 656

Table 85. Assembly 31: Duplex Unit and Offset Feeder II (continued)
Asm Index 31 19 20 21 22 23 24 25 C4 B4 B4 A3, A4 B4 B2 C1, C2 90H3379 NP NP 1 3 1 2 1 1 ? Grid Part Number Units Duplex unit and offset feeder II v Duplex gear C (in kit P/N 06L9998) (see page 580) v Duplex gear B (in kit P/N 06L9998) (see page 580) v Duplex gear A (in kit P/N 06L9998) (see page 580) v Offset gear (in kit P/N 06L9998) (see page 580) v Duplex motor v Return chute assembly v Clip Description

Appendix E. Duplex Unit Option 657

Appendix F. Envelope Tray Option


Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .659

Copyright IBM Corp. 1998

658

Parts Catalog
1 2 3 4

25
C C

hc2m509F

Appendix F. Envelope Tray Option 659

Table 86. Assembly 24: Envelope Tray Option


Asm Index 24 1 25 A3 C2 90H0721 90H3467 1 1 Grid Part Number Units Envelope Tray Option Envelope Tray Option with Cover A4 Cassette Cover Description

AsmIndex numbers not used: 2 to 24

Appendix F. Envelope Tray Option 660

Appendix G. 500-Sheet Paper Tray Option


Diagnostics . . . . . . . . . . . . 11 LOAD <size> IN TRAY n . . . 16 TRAY n MISSING . . . . . . 17 TRAY n OPTION ERROR . . 21 PAPER JAM . . . . . . . . . Wiring Diagram . . . . . . . . . . Removal Procedures, Adjustments Feeder Assembly . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Feed Housing Left . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Feed Housing Right . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Feeder Front Cover . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Feeder PWB . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Turn In Chute . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Turn Chute Assembly Aux.. . . . Removal . . . . . . . . . . . .
Copyright IBM Corp. 1998

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.663 .663 .663 .664 .664 .665 .666 .666 .667 .667 .668 .668 .669 .670 .670 .671 .672 .673 .673 .674 .674 .675 .676 .676 .677 .678 .678 661

Replacement. . . . . . . . . Cassette Guide Assembly L . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette No Paper Sensor . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette Guide Assembly R . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette No Paper Actuator . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roll . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Solenoid . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Electromagnetic Clutch Aux. . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Turn Roll Assembly . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Parts Catalog . . . . . . . . . . Assembly 20: Optional Tray 2/3 Assembly 21: Optional Tray 2/3

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.679 .680 .681 .681 .683 .683 .684 .685 .685 .686 .687 .687 .688 .689 .689 .690 .691 .691 .692 .693 .693 .694 .695 .695 .696 .697 .697 .700

Appendix G. 500-Sheet Paper Tray Option 662

Diagnostics 11 LOAD <size> IN TRAY n


Use this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.
Table 87. 11 LOAD <size> IN TRAY n
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No

16 TRAY n MISSING
Meaning: Paper Cassette (Tray 1), Tray 2 and/or Tray 3 are not in place. Action: Open and close the tray. If you have not installed the tray, do so at this time.
Table 88. 16 TRAY n MISSING
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No

Appendix G. 500-Sheet Paper Tray Option 663

17 TRAY n OPTION ERROR


A 500-sheet option is installed, but is not detected. Ensure that the option is installed correctly.
Table 89. 17 TRAY n OPTION ERROR
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No

21 PAPER JAM
Use this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.
Table 90. 21 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No

Appendix G. 500-Sheet Paper Tray Option 664

Wiring Diagram
P207 P/J P/J 904 204
FEED SOLENOID CASSETTE NO PAPER SENSOR

P202 P/J 203

FEEDER PWB
P201

P/J 205

P/J P/J TURN 906 206 CLUTCH

P207 P/J P/J 904 204


FEED SOLENOID CASSETTE NO PAPER SENSOR

P202 P/J 203

FEEDER PWB
P201

P/J 205

P/J P/J TURN 906 206 CLUTCH

P207

MCU

P202

FEEDER PWB
P201

P/J 18

P/J 20

HC2M858F

Appendix G. 500-Sheet Paper Tray Option 665

Removal Procedures, Adjustments Feeder Assembly


Asm-Index: 20-1, page 697.

2
hc2m707F

Figure 100. Feeder Assembly Removal

Appendix G. 500-Sheet Paper Tray Option 666

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the base engine and the feeder assembly. 3. Remove the two screws (1), using a stabilizer screwdriver, securing the feeder assembly to the base engine.

4. Lift the base engine to separate it from the feeder assembly.

Replacement
1. Rotate the feed roll (Asm-Index: 21-11, page 700) until its rubber surface faces up.

2. Lift the base engine and place it on the feeder assembly positioning the holes in the base engine to the bosses (2) on the feeder assembly. Attention: Move the base engine horizontally and slowly. 3. Using a stabilizer screwdriver, secure the base engine to the feeder assembly using the two screws.

Appendix G. 500-Sheet Paper Tray Option 667

Feed Housing Left


Asm-Index: 20-3, page 697.
1

3
hc2m708F

Figure 101. Feed Housing Left Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Remove the screw (1) securing the feed housing left (2) to the cassette guide assembly left (Asm-Index: 20-16, page 697). 4. Remove the four screws (3) securing the feed housing to the feeder assembly. 5. Remove the housing.

Appendix G. 500-Sheet Paper Tray Option 668

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 669

Feed Housing Right


Asm-Index: 20-4, page 697.
1

hc2m709F

Figure 102. Feed Housing R Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Remove the screw (1) securing the feed housing right to the cassette guide assembly right (2) (Asm-Index: 20-23, page 697).
Appendix G. 500-Sheet Paper Tray Option 670

4. Remove the four screws (3) securing the feed housing to the feeder assembly. 5. Remove the feed housing.

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 671

Feeder Front Cover


Asm-Index: 20-5, page 697.
1

3 3

hc2m710F

Figure 103. Feeder Front Cover Removal

Appendix G. 500-Sheet Paper Tray Option 672

Removal

1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feeder assembly (See page 666). 3. Remove the feed housing left (See page 668). 4. Remove the feed housing right (See page 670). 5. Remove the three screws (1) securing the feeder front cover (2). 6. Pressing the two bosses (3) located at the left and right end of the front cover, slide the cover to the front. 7. Move the feeder front cover downward to remove it.

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 673

Feeder PWB
Asm-Index: 20-11, page 697.

J202

J201

1
J203

2
hc2m711F

Figure 104. Feeder PWB Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Disconnect J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB.

Appendix G. 500-Sheet Paper Tray Option 674

Attention: Do not move the feeder PWB away from the feeder assembly (Asm-Index: 20-1, page 697). They are still connected by harnesses. 4. Remove the four screws (1) securing the feeder PWB (2) to the feeder assembly. 5. Disconnect J201 of the tray upper harness (Asm-Index: 20-27, page 697) and /J202 of the tray lower 2 harness (Asm-Index: 20-12, page 697) from the feeder PWB. 6. Remove feeder PWB from the feeder assembly.

Replacement
1. Reconnect J201 of the tray upper harness and J202 of the tray lower 2 harness to the feeder PWB. Attention: Do not damage the paper size switch on the feeder PWB during step 2. 2. Place the feeder PWB on the feeder assembly. 3. Secure the feeder PWB to the feeder assembly using four screws (silver, 6mm). 4. Reconnect J203 of the feeder harness to the feeder PWB. 5. Route the harnesses so as not to interfere with the function of the paper Size switch. 6. Reinstall the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 675

Turn In Chute
Asm-Index: 20-14, page 697.

1
hc2m712F

Figure 105. Turn In Chute Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Open the turn chute assembly aux (1). (Asm-Index: 20-15, page 697). 4. Flex the left side arm of the turn in chute (2) and remove its hinge hole from the boss on the cassette guide assembly left (Asm-Index: 20-16, page 697). 5. Remove the turn in chute from the cassette guide assembly right (Asm-Index: 20-23, page 697).
Appendix G. 500-Sheet Paper Tray Option 676

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 677

Turn Chute Assembly Aux.


Asm-Index: 20-15, page 697.

hc2m713F

Figure 106. Turn Chute Assembly Aux. Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the turn in chute (See page 676). 3. Hold the chute assembly open and slide it to the left. 4. Lift the rear of the feeder assembly (Asm-Index: 20-1, page 697) and pull the right side of the turn chute down. 5. Slide the chute to the right and remove it from the feeder assembly. 6. Lower the feeder assembly.
Appendix G. 500-Sheet Paper Tray Option 678

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 679

Cassette Guide Assembly L


Asm-Index: 20-16, page 697.

3 2
J203 J204

2
J206

1
hc2m714F

Figure 107. Cassette Guide Assembly Left Removal

Appendix G. 500-Sheet Paper Tray Option 680

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678). 5. Disconnect: v J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB (Asm-Index: 20-11, page 697) v J204 from the feed solenoid (Asm-Index: 21-18, page 700) v J206 of the feeder harness connecting to the electromagnetic clutch aux. (Asm-Index: 21-19, page 700) Release the clutch side of the feeder harness from the clamp. Release the three screws (1) securing the cassette guide assembly L (2) from outside of the frame. Remove the screw (3) securing the cassette guide from the front bottom inside the cassette well. Using a at blade screwdriver, push the three hooks (4) at the bottom of the cassette guide assembly L, up and in, one by one, to release them from the frame. 10. Tilt the cassette guide, pulling its bottom edge from the inside of the cassette well. 11. Ensure that the three upper hooks of the cassette guide are released from the frame. 12. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator (Asm-Index: 20-26, page 697) 13. Push all harnesses on the cassette guide to free them from the frame. 14. Remove the cassette guide from the feeder assembly. 6. 7. 8. 9.

Replacement
1. Hold the cassette guide assembly left with the bottom to the right and top to the left so that it will not interfere with the cassette no paper actuator.
Appendix G. 500-Sheet Paper Tray Option 681

2. 3. 4. 5. 6. 7. 8. 9.

Insert the cassette guide into the paper cassette well. Insert all connectors on the cassette guide through their openings in the frame. Place the upper three hooks of the cassette guide in their respective holes in the frame. Pull the feeder harness through the opening in the frame to keep them from being pinched between the cassette guide and the frame. Press the bottom of the cassette guide, tilting it up until the upper and lower hooks lock into position. Secure the cassette guide to the feeder assembly using three screws (gold, self tapping, 8mm). Insert harnesses to clamps. Reconnect: v J203 of the feeder harness to the feeder PWB v J204 to the feed solenoid v J906 of the feeder harness connecting to the electromagnetic clutch aux.

Attention: Route the harnesses so as not to interfere with the gears. 10. Ensure the cassette no paper actuator functions properly. 11. Reinstall the turn chute assembly aux. (See page 678). 12. Reinstall the turn in chute (See page 676). 13. Reinstall the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 682

Cassette No Paper Sensor


Asm-Index: 20-21, page 697.

J205

hc2m715F

Figure 108. Cassette No Paper Sensor Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676).

Appendix G. 500-Sheet Paper Tray Option 683

4. Swing the armature (1) of the cassette no paper actuator (Asm-Index: 20-26, page 697) to the rear so that the actuator is away from the cassette no paper sensor (2). 5. Open the turn in chute (Asm-Index: 20-14, page 697). 6. Use a small at blade screwdriver to release the hooks of the no paper sensor, located at the inside of the feeder assembly (Asm-Index: 20-1, page 697) (work from the rear of the frame), from the feeder assembly. Attention: Do not move the cassette no paper sensor away since it is connected with a harness. 7. Disconnect J205 from the sensor. 8. Remove the sensor.

Replacement
1. Swing the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette no paper sensor. 2. Reconnect J205 to the no paper sensor. 3. Position the sensor in the opening in the frame, and press the sensor into place until the hooks of the sensor snap into position. 4. Tack the extra length of the harness into the wiring channel of the cassette guide so that the harness does not interfere with the gears. 5. Reinstall the turn in chute (See page 676). 6. Reinstall the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 684

Cassette Guide Assembly R


Asm-Index: 20-23, page 697.

1 2 3 3
hc2m716F

Figure 109. Cassette Guide Assembly R Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing right (See page 670). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678).
Appendix G. 500-Sheet Paper Tray Option 685

5. Remove the three screws (1) securing the cassette guide assembly R (2) to the feeder assembly (Asm-Index: 20-1, page 697). 6. Using a at blade screwdriver, push the three hooks (3) at the bottom of the cassette guide assembly R, up and in, one by one, to release them from the frame of the feeder assembly. 7. Tilt the cassette guide, pulling its bottom edge from the inside of the frame. 8. Ensure that the three upper hooks of the cassette guide are released from the frame. 9. Remove the cassette guide from the feeder assembly.

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 686

Cassette No Paper Actuator


Asm-Index: 20-26, page 697.

hc3u717F

Figure 110. Cassette No Paper Actuator Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678). 5. Remove the cassette guide assembly left (See page 680).

Appendix G. 500-Sheet Paper Tray Option 687

6. Slide the cassette no paper actuator (1) to the right. 7. Release the left end of the no paper actuator from the frame. 8. Slide the actuator to the left and remove it from the frame.

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 688

Feed Roll
Asm-Index: 21-11, page 700.
4 2 3

5
hc2m718F

Figure 111. Feed Roll Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678).

Appendix G. 500-Sheet Paper Tray Option 689

5. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page 700) and the frame. 6. Remove the E-ring (3) securing the feed core (Asm-Index: 21-13, page 700) to the feed shaft assembly (4) (Asm-Index: 21-12, page 700). 7. Remove the feed core, the feed core spring (Asm-Index: 21-14, page 700), and the feed gear from the feed shaft assembly. 8. Rotate the feed shaft assembly until the rubber surface of the feed roll (5) faces to the front. Attention: Do not damage the cassette no paper actuator (Asm-Index: 20-26, page 697) and the rubber rolls. 9. Hold the feed shaft assembly away from the no paper actuator. 10. Press the hook of the feed roll to the front to remove it from the feed shaft.

Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft. Attention: Ensure that the cams are located between the left and right pairs of the feed rolls. 3. Reinstall the feed core, the feed core spring, and the feed gear (Asm-Index: 21-15, page 700) from the feed shaft assembly (Asm-Index: 21-12, page 700). 4. Reinstall the E-ring that secures the feed core to the feed shaft assembly. 5. Rotate the feed shaft assembly manually and place the rubber surface of the feed roll upper position. 6. Reinstall the feed spring (Asm-Index: 21-17, page 700) on the feed gear and the frame. 7. Reinstall the turn chute assembly aux. (See page 678). 8. Reinstall the turn in chute (See page 676). 9. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 690

Feed Solenoid
Asm-Index: 21-18, page 700.

J204

hc2m720F

Figure 112. Feed Solenoid Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 691

3. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page 700) and the frame. 4. Disconnect J204 of the feed solenoid (3) from the feeder harness (Asm-Index: 20-22, page 697) on the cassette guide assembly L (Asm-Index: 20-16, page 697). 5. Remove the screw (4) securing the feed solenoid to the cassette guide assembly. 6. Remove the solenoid from the cassette guide.

Replacement
1. Place the feed solenoid in position and secure it using a screw (silver, 6mm). 2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly L. Attention: Route the harness so that it does not touch the gears. 3. Reinstall the feed spring between the feed gear and the feed solenoid. 4. Ensure that the armature of the feed solenoid xes the feed gear at the upper position, and releases at the lower position. 5. Rotate the feed shaft to place the rubber surface of the feed roll (Asm-Index: 21-11, page 700) up until the feed gear is released from the feed idler gear (Asm-Index: 21-22, page 700). 6. Reinstall the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 692

Electromagnetic Clutch Aux.


Asm-Index: 21-19, page 700.

4 5 2

J206

3 2

hc2m721F

Figure 113. Electromagnetic Clutch Aux. Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the feed housing right (See page 670). 4. Remove the turn in chute (See page 676).
Appendix G. 500-Sheet Paper Tray Option 693

5. Remove the turn chute assembly aux. (See page 678). 6. Remove the E-ring (1) at the right end of the turn roll assembly (2) (Asm-Index: 21-20, page 700). 7. Remove the right turn bearing (3) (Asm-Index: 21-21, page 700). 8. Disconnect J206 from the electromagnetic clutch aux (4). 9. Slide the turn roll assembly (Asm-Index: 21-20, page 700) to the left to remove the left turn bearing from the frame. 10. Remove the E-ring (5) securing the electromagnetic clutch to the turn roll assembly and remove the clutch from the turn roll.

Replacement
1. Place the electromagnetic clutch aux. to the turn roll assembly. 2. Reinstall the E-ring to secure the electromagnetic clutch to the turn roll assembly. 3. Insert the turn roll assembly from the left and insert the notch of the electromagnetic clutch to the arm of the frame. 4. Insert the left side turn bearing to the frame. 5. Install the right side turn bearing to the opening in the frame and secure the bearing using an E-ring. 6. Reconnect J206 to the electromagnetic clutch. Note: Route the harness so that it does not touch the gears. 7. Reinstall the turn chute assembly aux. (See page 678). 8. Reinstall the turn in chute (See page 676). 9. Reinstall the feed housing right (See page 670). 10. Reinstall the feed housing left (See page 668).

Appendix G. 500-Sheet Paper Tray Option 694

Turn Roll Assembly


Asm-Index: 21-20, page 700.

hc2m722F

Figure 114. Turn Roll Assembly Removal

Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the feed housing right (See page 670). 4. Remove the turn in chute (See page 676). 5. Remove the turn chute assembly aux. (See page 678). 6. Remove the electromagnetic clutch aux. (See page 693).

Appendix G. 500-Sheet Paper Tray Option 695

7. Remove the right side E-ring (1) securing the turn bearing (2) (Asm-Index: 21-21, page 700) to the turn roll assembly (3) and remove the right side turn bearing. 8. Remove the two left side E-rings (4) securing the turn bearing (5) to the turn roll assembly and remove the left side turn bearing. 9. Slide the turn roll assembly to the left and release its right end from the frame. 10. Slide the turn roll assembly to the right then backward and remove it from the frame.

Replacement
Reverse the Removal procedure.

Appendix G. 500-Sheet Paper Tray Option 696

Parts Catalog Assembly 20: Optional Tray 2/3 Feeder I


1 2 3 4

hc2m704F

Appendix G. 500-Sheet Paper Tray Option 697

Table 91. Assembly 20: Optional Tray 2/3 Feeder I


Asm Index 20 1 1 2 3 4 5 11 12 14 15 16 17 18 19 20 21 22 28 23 A3 A3 A2 A3 A4 A3 B4 B4 B2 C1 B2 C2 C3 C3 B2 C3 C3 C3 B1 90H0717 90H3341 NP NP NP NP 90H0771 90H0772 90H0773 90H3348 90H0775 NP NP NP NP 90H0776 90H0772 NP 90H0777 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 1 1 1 1 Grid Part Number Units Optional tray feeder I 500 Sheet Feeder w/A4 Cassette (with 20-220-28) 500 Sheet Feeder w/A3 Cassette (with 20-220-28) v Feeder Frame Assembly (same as 21-2) v Feed housing, left v Feed housing, right v Feeder front housing v Feeder PWB v Tray lower2 harness v Turn in chute v Turn chute assembly, auxiliary v Cassette guide assembly, left (with 20-1720-22, 20-28) v v Cassette guide L v v Size actuator v v Size actuator spring v v Low paper actuator v v Cassette no paper sensor v v Feeder harness v v Cassette guide cap v Cassette guide assembly, right (with 20-24, 20-25) Description

Appendix G. 500-Sheet Paper Tray Option 698

Table 91. Assembly 20: Optional Tray 2/3 Feeder I (continued)


Asm Index 20 24 25 26 27 B1 B1 B2 B4 NP NP 90H0778 90H3352 1 1 1 1 Grid Part Number Units Optional tray feeder I v v Cassette guide R v v Cassette stopper spring v Cassette no paper actuator v Tray upper harness Description

AsmIndex numbers not used: 6 to 10, 13

Appendix G. 500-Sheet Paper Tray Option 699

Assembly 21: Optional Tray 2/3 Feeder II


1 2 3 4

hc2m705F

Appendix G. 500-Sheet Paper Tray Option 700

Table 92. Assembly 21: Optional Tray Feeder II


Asm Index 21 1 1 2 3 11 12 13 14 15 17 16 18 19 20 21 22 23 B4 B4 B4 B4 A1, B3 A4 C4 C2 A1 B3 B3, C3 90H0782 90H3355 90H0784 1 1 2 1 2 A2 A2 A2 B2 B2, C2 C2 90H0780 90H0781 90H0717 90H3341 NP NP 1 1 1 1 4 1 1 1 1 1 1 2 Grid Part Number Units Optional tray feeder II 500 Sheet Feeder w/A4 Cassette (with 21-221-24) 500 Sheet Feeder w/A3 Cassette (with 21-221-24) v Feeder frame assembly v Feeder connector v Feed roll (in feed roll kit 90H0779) v Feed shaft assembly v Feed core assembly kit (with 21-1315, 21-17) v v Feed core (in kit P/N 90H0781) (see page 580) v v Feed core spring (in kit P/N 90H0781) (see page 580) v v Feed gear (in kit P/N 90H0781) (see page 580) v v Feed spring (in kit P/N 90H0781) (see page 580) v Feed bearing (in kit P/N 06L9997) (see page 580) v Feed solenoid v Electromagnetic clutch, auxiliary v Turn roll assembly v Turn bearing (in kit P/N 90H0786) (see page 580) v Feed idler gear (in kit P/N 90H3384) (see page 580) v Out idler gear (in kit P/N 90H3384) (see page 580) Description

Appendix G. 500-Sheet Paper Tray Option 701

Table 92. Assembly 21: Optional Tray Feeder II (continued)


Asm Index 21 24 A4 1 Grid Part Number Units Optional tray feeder II v In idler gear (in kit P/N 90H3384) (see page 580) Description

AsmIndex numbers not used: 4 to 10

Appendix G. 500-Sheet Paper Tray Option 702

Appendix H. 2000-Sheet Input Drawer Option


Important Information . . . . . . . Diagnostics . . . . . . . . . . . . 03 2000-SHEET COVER OPEN . 15 TRAY n NOT READY . . . . 17 2000 SHEET INPUT ERROR 26 PAPER JAM . . . . . . . . . Wiring Diagram . . . . . . . . . . Removal Procedures, Adjustments 2000-Sheet Input Drawer . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Foot . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . HCF Tray Assembly . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Side Plate . . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Front Cover . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Lift Up Motor . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Bottom Plate . . . . . . . . . . .
Copyright IBM Corp. 1998

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.707 .708 .708 .709 .710 .711 .716 .717 .717 .718 .718 .719 .720 .720 .721 .722 .722 .723 .724 .724 .725 .725 .726 .727 .728 .728 .729 703

Removal . . . . . . . . . . . Replacement. . . . . . . . . Near Empty Sensor . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Lower Position Sensor . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Size Sensor . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Harness . . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Chute . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Unit Assembly . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Right Hand Cover Open Switch Removal . . . . . . . . . . . Replacement. . . . . . . . . Exit Sensor . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roller Kit. . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Upper Limit Sensor . . . . . .

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.730 .730 .731 .731 .732 .733 .733 .734 .735 .735 .736 .737 .737 .738 .739 .740 .740 .741 .741 .742 .743 .743 .744 .745 .746 .746 .747 .748 .748 .750

Appendix H. 2000-Sheet Input Drawer Option 704

Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Level Sensor . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roller . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Tray Set Sensor 1,2 . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Left Hand Cover Open Switch . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Motor . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . LVPS. . . . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Rear Cover Kit . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Roll Kit . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Flat Harness . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Belt . . . . . . . . . . . . . .

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.750 .751 .752 .752 .753 .754 .754 .755 .756 .756 .757 .758 .758 .759 .760 .760 .761 .762 .762 .763 .764 .765 .765 .766 .767 .767 .768 .768 .769 .770

Appendix H. 2000-Sheet Input Drawer Option 705

Removal . . . . . . . . Replacement. . . . . . Connector Kit . . . . . . Removal . . . . . . . . Replacement. . . . . . Parts Catalog . . . . . . . Assembly 40: 2000-Sheet Assembly 41: 2000-Sheet Assembly 42: 2000-Sheet

. . . . . . . . . . . . . . . . . . Input Input Input

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drawer I . . Drawer Tray Drawer II . .

. . . . . . . . .

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.770 .771 .772 .773 .773 .774 .774 .776 .778

Appendix H. 2000-Sheet Input Drawer Option 706

Important Information
Note: When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches. One cord connects the option to the wall outlet, and the other connects the option to the printer. AC power is present on both machines even when both power switches are turned off.

Appendix H. 2000-Sheet Input Drawer Option 707

Diagnostics 03 2000-SHEET COVER OPEN


One of the two interlock switches on the rear cover of the HCF is not activated. Note: This error can occur if the cover is opened, but the jammed paper is not removed. Switch the power off and then on. If 26 PAPER JAM occurs, go to 26 PAPER JAM on page 711. Use D21 SENSOR TEST on page 261 to isolate help isolate the problem.
Table 93. 03 2000-SHEET COVER OPEN
Step Actions and Questions SUSPECT COMPONENTS v Right Cover Open Switch (Asm-Index: 42-9, page 778), see page 743 for the removal procedure. v Left Cover Open Switch (Asm-Index: 42-20, page 778), see page 758 for the removal procedure. v HCF Rear Cover (Asm-Index: 42-2, page 778), see page 764 for the removal procedure. v Flat harness (Asm-Index: 42-29, page 778), see page 768 for the removal procedure. v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for the removal procedure. Yes No

Appendix H. 2000-Sheet Input Drawer Option 708

15 TRAY n NOT READY


The paper tray for the 2000-Sheet Input Drawer (High Capacity Feeder; HCF) is open, or the elevator for the stack of paper is in motion. If this error displays, wait 2 minutes. If it becomes a 26 PAPER JAM, go to 26 PAPER JAM on page 711.
Table 94. 15 TRAY n NOT READY
Step Actions and Questions SUSPECT COMPONENTS v Obstruction from Right Caster v Tray Set Sensor 1 (Asm-Index: 42-18, page 778), see page 756 for the removal procedure. v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for the removal procedure. v Harness (Asm-Index: 41-16, page 776), see page 737 for the removal procedure. v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for the removal procedure. Yes No

Appendix H. 2000-Sheet Input Drawer Option 709

17 2000 SHEET INPUT ERROR


The 2000-Sheet Input Option (High Capacity Feeder; HCF) is installed, but is not detected. Ensure that the option is installed correctly.
Table 95. 17 2000 SHEET INPUT ERROR
Step Actions and Questions SUSPECT COMPONENTS v HCF power problem (The HCF should be plugged to the wall. The printer should be plugged to the HCF. Both power switches must be on). v HCF LVPS (Asm-Index: 42-25, page 778)), see page 762 for the removal procedure. v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for the removal procedure. v Harness (Asm-Index: 41-16, page 776), see page 737 for the removal procedure. Yes No

Appendix H. 2000-Sheet Input Drawer Option 710

26 PAPER JAM
There is a jam condition at the 2000-Sheet Input Option (High Capacity Feeder, HCF). This error is posted for several different conditions: v Paper never arrived at the HCF exit sensor actuator, located on the back door (chute) of the HCF. v Paper arrived at the the HCF exit sensor, but it never deactuated. v HCF tray (elevator) does not travel up or down correctly. (A 15 TRAY n NOT READ message will probably display rst and then turn into a 26 PAPER JAM message.) Notes: 1. When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches. One cord connects the option to the wall outlet, and the other connects the option to the printer. AC power is present on both machines even when both power switches are turned off. 2. If HCF option is installed directly beneath the printer, it is Tray 2. If a 500-sheet option is installed beneath the printer, it is Tray 2 and the HCF is Tray 3. In this MAP, generally the term Tray n is used. 3. It is normal for the HCF tray (elevator) to move after the printer power is turned on. It will move the tray up toward the top position where a sensor checks for a stack of paper. If no paper is detected, the tray moves all the way down (the position needed for paper loading). While the tray is moving, the operator panel may display a 15 2000-SHEET INPUT NOT READY message. 4. When the HCF tray is opened , the 15 2000-SHEET INPUT NOT READY message will display. The elevator should move down until it reaches its lowest position. After the tray is closed, the elevator should move up until the top of the stack of paper reaches the top position. (If there is no paper, it will move back down.) SUSPECT COMPONENTS 1. HCF pick problem (paper never leaves HCF tray, but paper loading is OK): v Feed Roller (Asm-Index: 41-14, page 776) v Feed Motor (Asm-Index: 42-28, page 778)
Appendix H. 2000-Sheet Input Drawer Option 711

v Flat Harness (Asm-Index: 42-29, page 778) 2. HCF transport problem (paper gets picked and starts to leave the tray, but does not continue into paper path): v Transport Motor (Asm-Index: 42-21, page 778) v Transport Belt (Asm-Index: 42-22, page 778) v Transport Gear (Asm-Index: 42-23, page 778) v Transport Roll (Asm-Index: 42-7, page 778) - test with D68 HCF MOTOR (HCF Transport Motor) on page 291 v Flat Harness (Asm-Index: 42-7, page 778) v Paper Chute (Asm-Index: 42-5, page 778) 3. HCF elevator problem: v Test with D44 HCF UP (Tray Lifts) on page 273 & D45 HCF DOWN (Tray Lowers) on page 275 v Lift up motor (Asm-Index: 41-10, page 776) v Lower position sensor (Asm-Index: 41-12, page 776) v Upper limit sensor (Asm-Index: 42-11, page 778), test with D21 SENSOR TEST on page 261 v Paper level sensor (Asm-Index: 42-2, page 778) 4. Sensor Problems that cause false 26 errors after power is turned on: v HCF exit sensor (42-10)- test with D21 SENSOR TEST on page 261 v Tray set #2 sensor (42-19) - 15 message will occur rst - test with D21 SENSOR TEST on page 261 5. Sensor Problems that cause 26 during printing from HCF: v HCF exit sensor actuator (Asm-Index: 42-5, page 778) v HCF exit sensor (42-10) - test with D21 SENSOR TEST on page 261 v No paper sensor (Asm-Index: 42-28, page 778) - test with D21 SENSOR TEST on page 261
Appendix H. 2000-Sheet Input Drawer Option 712

v Paper level sensor (Asm-Index: 42-2, page 778) Note: The HCF near empty sensor is not used 6. General FRUs for 26 Jam (valid in all of the lists above) v HCF LVPS (Asm-Index: 42-25, page 778) v Cables (check all connections at HCF LVPS) v HCF option v MCU
Table 96. 26 PAPER JAM
Step Actions and Questions Switch on the printer power and the HCF power. Wait until the printer is ready or an error displays. Is there an error? Wait 2 minutes to see if the 15 error turns into a 26 PAPER JAM. 2. Does a 26 PAPER JAM display? Open the rear door of the HCF. Is there any paper or paper scraps in the path? 3. Remove the paper. Open and close the top cover to reset the error. Go to step 4. Yes No

1.

If the initial error is Go to step 4 26, go to step 3. If the initial error is 15, go to step 2. Go to step 4 For other errors, go to Chapter 1. Getting Started on page 25. False 26 errors. Go to Suspect Components list 4, then 3 and 6.

Appendix H. 2000-Sheet Input Drawer Option 713

Table 96. 26 PAPER JAM (continued)


Step ELEVATOR FUNCTION: 4. Put paper in the HCF tray. The elevator should go down when you open the tray and then go up when you close the tray. A 15 message is normal during tray motion, but it should not turn into a 26. Does the Elevator function correctly? Print from the HCF: a. Set PAPER MENU/SOURCE=Tray2 or Tray3. b. Ensure that there is paper in the HCF. c. Go OFFLINE. d. Use TEST MENU/CONFIG PAGE. Does the CONFIG page print correctly? a. Remove the paper from the HCF. b. Set PAPER MENU/TRAY SWITCH=off. c. Try to print another CONFIG page. Does an 11 LOAD message occur? Open the rear door of the HCF. 7. Did the paper start to leave the HCF tray? Go to step 8 Unknown problem. If the problem persists, install a new HCF option. If a 26 error occurs, install a new HCF no paper sensor (Asm-Index: 42-28, page 778). Pick problem. Go to Suspect Components, lists 1 and 6. Go to step 6 For 26 PAPER JAMs, go to step 7. For other problems, go to Start of Call. Actions and Questions Yes Go to step 5 No Go to Suspect Components, lists 3 and 6.

5.

6.

Appendix H. 2000-Sheet Input Drawer Option 714

Table 96. 26 PAPER JAM (continued)


Step Actions and Questions Yes No Transport problem. Go to Suspect Components, lists 2 and 6.

8.

Run D68 (see D68 HCF MOTOR (HCF Transport Motor) on page 291). You Go to step 9 will have to override the HCF rear cover switches to watch the transport roll move. Does the Transport Roll move? You have a problem caused by one of the following: v HCF exit actuator (Asm-Index: 42-5, page 778)

9.

v HCF exit sensor (42-10) - test with D21 SENSOR TEST on page 261 v Paper path obstruction

10.

End of Diagnostic

Appendix H. 2000-Sheet Input Drawer Option 715

Wiring Diagram
LVPS
LIFT UP MOTOR CONTROL P/J:XS1 10 9 1 2 5 6 3 4 7 8 P/J:XS2 12 11 25 26 P/J:XS3 P/J:XS4 RXD 14 1 TXD 16 2 SG 12 3 SG 13 4 FEEDER CHECK 9 5 3 4 5 FEED MOTOR CONTROL 1 2 6 7 8 22 23 24 9 10 13 14 15 TRANSPORT MOTOR CONTROL 18 19 20 21 16 17 27 28 MAIN SWITCH
GND GND DC21 DC22 DC22 SWHD SG SWPL(TTL) SG SWPSZ(TTL) FG

CPU

P/J:M1 (+) (-) P/J:S2 1 3 P/J:S1 1 3 P/J:S3 1 3 P/J:S7 2 1 P/J:S11 1 3 P/J:P1 3 2 1 5 4 P/J:P2 1 2 3 P/J:S10 1 2 3 P/J:S6 1 2 P/J:S8 1 2 3 P/J:M2 1 2 3 4 P/J:S9 1 2 P/J:S12 1 2

LIFT UP MOTOR LOWER POSITION SENSOR

NEAR EMPTY SENSOR

SIZE SENSOR

DC21 SWHU1 SWHU1 SWHU2 +5VDC LSPE(TTL) SG DC11 DC12 +5VDC ENCOD(TTL) SG +5VDC LSPL(TTL) SG SWCPR(TTL) SG +5VDC LSPEX(TTL) SG SM1 SM2 SM3 SM4 SWDO1(TTL) SG SWDO1(TTL) SWDO(TTL)

TRAY SET SENSOR 2

UPPER LIMIT SENSOR

NO PAPER SENSOR

Base Engine or 2ND TRAY

FEED MOTOR

ENCODER

SG

PAPER LEVEL SENSOR

TRAY SET SENSOR 1

SENSOR

TRANSPORT MOTOR

LEFT HAND COVER OPEN SWITCH RIGHT HAND COVER OPEN SWITCH

AC to DC

SERVICE CONNECT

AC INLET

hc2m089F

This is an internal wiring of the FEED ROLLER KIT, therefore the P/J No. and Pin No. are omitted.

Appendix H. 2000-Sheet Input Drawer Option 716

Removal Procedures, Adjustments 2000-Sheet Input Drawer


Asm: 40, page 774.

[1]

hc2m072F

Figure 115. 2000-Sheet Input Drawer Removal

Appendix H. 2000-Sheet Input Drawer Option 717

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Remove the Paper Cassette from the Base Engine or Option Tray. Remove the two screws (1) that lock the HCF to the Base Engine.

5. Lift the Base Engine to separate the Base Engine and the HCF. Remove the HCF.

Replacement

Attention: In the step below, match the HCF positioning boss with the Base Engine positioning boss. Gently place the main unit on the HCF; make sure it goes on straight. 1. Lift the Base Engine and install it on the HCF. 2. Lock the Base Engine and the HCF with the two screws. 3. Install the paper cassette, if Base Engine or Option Tray is installed.

Appendix H. 2000-Sheet Input Drawer Option 718

Foot
Asm-Index: 40-3, page 774.

hc2m024F

2 2 1

Figure 116. Foot Removal

Appendix H. 2000-Sheet Input Drawer Option 719

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the four screws (1) that lock the Foot (2). Remove the Foot.

Replacement
Reverse the Removal procedure.

Appendix H. 2000-Sheet Input Drawer Option 720

HCF Tray Assembly


Asm-Index: 41-1, page 776.
[2] [1]

1 2
hc2m023F

1
[3] [4]

Figure 117. HCF Tray Assembly Removal

Appendix H. 2000-Sheet Input Drawer Option 721

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Pull out the HCF Tray Assembly. 4. Disconnect the P/J:XS1 (See 1 in the gure). Attention: In the next step, carefully sqeeze the release hooks on the clamp from the backside. The hooks break easily. 5. Remove the harness clamp (See 2 in the gure). 6. Remove the two screws (1) securing the HCF Tray Assembly (2). 7. Remove the hooks (See 3 in the gure) on the front side of the slide rails. (The hooks lock the HCF Tray Assembly.) Attention: When you remove the HCF Tray Assembly in the step below, support the Tray (rear) so that it will not fall. 8. Remove the hooks (See 4 in the gure) on the rear side of the slide rails. (The hooks lock the HCF Tray Assembly.)

Replacement
1. Install the rear hooks on the HCF Tray Assembly. 2. Install the front hooks on the HCF Tray Assembly. 3. Lock the HCF Tray Assembly with the two screws . 4. Install the harness clamp. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 5. Connect the P/J:XS1. 6. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 722

Side Plate
Asm-Index: 41-3 and 41-13, page 776.

1 1

hc2m025F

Figure 118. Side Plate Removal

Appendix H. 2000-Sheet Input Drawer Option 723

Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Turn the keys that lock the Side Plates (1). Remove the Side Plates.

Replacement
Reverse the Removal procedure.

Appendix H. 2000-Sheet Input Drawer Option 724

Front Cover
Asm-Index: 41-7, page 776.

hc2m026F

Figure 119. Front Cover Removal

Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the four screws (1) that lock the Front Cover (2). Remove the Front Cover.
Appendix H. 2000-Sheet Input Drawer Option 725

Replacement
Attention: When you install the Front Cover in the step below, make sure that all the hooks are in place. 1. Install the Front Cover. 2. Lock the Front Cover with the four screws. 3. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 726

Lift Up Motor
Asm-Index: 41-10, page 776.

1
[2] Black + Red P/J:M1-(+) P/J:M1-(-) [1]

hc2m027F

Figure 120. Lift Up Motor Removal

Appendix H. 2000-Sheet Input Drawer Option 727

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Front Cover (See page 725).

5. Disconnect the P/J :M1. Attention: When you remove the Lift Up Motor in the steps below, place an object or your hand on the Bottom Plate to prevent it from springing up. 6. Remove the two screws that lock the Lift Up Motor. You can also remove the motor by just loosening them. 7. Remove the E-ring. 8. Remove the Lift Up Motor.

Replacement
1. Install the Lift Up Motor. 2. Install the E-ring. Attention: When you lock the Lift Up Motor in the step below, the tube washer should not overlap the positioning post. (See 1 in the gure.) 3. Lock the Lift Up Motor with the two screws. Attention: In the step below, check the cable color when connecting the P/J. If the P/J is not connected properly, the system malfunctions or may be damaged. (See 2 in the gure). When you connect the P/J in the step below, make sure that the harness or other components are not touching the motors rotating components.If they come in contact with the rotating components, they will be damaged. 4. Connect the P/J :M1. 5. Install the Front Cover (See page 725). 6. Insert the HCF Tray Assembly into HCF.

Appendix H. 2000-Sheet Input Drawer Option 728

Bottom Plate
Asm-Index: 41-2, page 776.

[2] [1]

1
[3]

1
hc2m046F

Figure 121. Bottom Plate Removal

Appendix H. 2000-Sheet Input Drawer Option 729

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Plates (See page 723).

5. Remove the locks (see 1 in the gure) on the Bottom Plate (1) (use a screwdriver if necessary). 6. Lift the back side of the Bottom Plate, remove the Bottom Plate (See 2 in the gure).

Replacement
Attention: When you install the Bottom Plate in the step below, make sure that the rear roller in the Lift Up mechanism has been properly installed on the roller guide of the Bottom Plate (See 3 in the gure). 1. Install the Bottom Plate. 2. Lock the Bottom Plate (use a screwdriver if necessary). 3. Install the Side Plates (See page 723). 4. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 730

Near Empty Sensor


Asm-Index: 41-11, page 776.

hc2m028F

Figure 122. Near Empty Sensor Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Pull out the HCF Tray Assembly.
Appendix H. 2000-Sheet Input Drawer Option 731

4. Remove the Front Cover (See page 725). 5. Remove the Near Empty Sensor. 6. Disconnect the P/J:S1.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S1. Attention: In the step below, install the Near Empty Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Near Empty Sensor (1). 3. Install the Front Cover (See page 725). 4. Insert the HCF Tray Assembly.

Appendix H. 2000-Sheet Input Drawer Option 732

Lower Position Sensor


Asm-Index: 41-12, page 776.

hc2m029F

Figure 123. Lower Position Sensor Removal

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Panels (See page 723).
Appendix H. 2000-Sheet Input Drawer Option 733

5. Remove the Bottom Plate (See page 729). 6. Remove the Lower Position Sensor (1). 7. Disconnect the P/J:S2.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S2. Attention: In the step below, install the Lower Position Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Lower Position Sensor. 3. Install the Bottom Plate (See page 729). 4. Install the Side Plates (See page 723). 5. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 734

Size Sensor
Asm-Index: 41-15, page 776.

hc2m073F

Figure 124. Size Sensor Removal

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Plates (See page 723).
Appendix H. 2000-Sheet Input Drawer Option 735

5. Remove the Bottom Plates (See page 729). 6. Remove the Size Sensor (1). 7. Disconnect the P/J:S3.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S3. Attention: In the step below, install the Size Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Size Sensor. 3. Install the Bottom Plate (See page 729). 4. Install the Side Plates (See page 723). 5. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 736

Harness
Asm-Index: 41-16, page 776.
[2] [1]

[3]

[4]

[7]

White Gray Blue

Orange [5]

[8] [6] Green

Black
+

Brown

Red

hc2m078F

Figure 125. Harness Removal

Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Disconnect the P/J:XS1 (See 1 in the gure). Remove the Front Cover (See page 725).

6. Remove the Bottom Plate (See page 729). 7. Remove the Holder (See 2 and 3 in the gure). 8. Remove the cable clamp.
Appendix H. 2000-Sheet Input Drawer Option 737

9. Disconnect the P/Js that are connected to the following: Near Empty Sensor, Size Sensor , Lower Position Sensor and Lift Up Motor. 10. Remove the Harness (1).

Replacement
1. Install the Harness. Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 2. Connect the P/Js to the following: Near Empty Sensor, Size Sensor, Lower Position Sensor and Lift Up Motor. 3. Install the cable clamp. 4. Install the Holder. 5. Install the Bottom Plate (See page 729). 6. Install the Front Cover (See page 725). Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 7. Connect the P/J:XS1. 8. Insert the HCF Tray Assembly into the HCF.

Appendix H. 2000-Sheet Input Drawer Option 738

Paper Chute
Asm-Index: 42-5, page 778.

[1]

hc2m032F

Figure 126. Paper Chute Removal

Appendix H. 2000-Sheet Input Drawer Option 739

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Rear Cover Kit (1) from the HCF (See page 764). 4. Remove the Paper Chute (2) from the Rear Cover Kit.

Replacement
Attention: When you install the Paper Chute in the step below, make sure that the four springs are installed properly, otherwise the system will malfunction (See 1 in the gure). 1. Install the Paper Chute to the Rear Cover Kit. 2. Install the Rear Cover Kit to the HCF (See page 764).

Appendix H. 2000-Sheet Input Drawer Option 740

Transport Unit Assembly


Asm-Index: 42-7 to 42-24, and 42-29, page 778.

1
hc2m045F

Figure 127. Transport Unit Assembly Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.
Appendix H. 2000-Sheet Input Drawer Option 741

3. Remove the Rear Cover Kit from the HCF (See page 764). 4. Roll out the HCF Tray Assembly from the HCF. 5. Disconnect the P/J:XS2 from LVPS. Attention: When you remove the screws in the step below, support the Transport Unit Assembly rmly with your hand so that it will not fall. 6. Remove the two screws (1) securing the Transport Unit Assembly (2). 7. Remove the Transport Unit Assembly.

Replacement
1. Install the Transport Unit Assembly. 2. Secure the Transport Unit Assembly with the two screws. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 3. Connect the P/J:XS2 to LVPS. 4. Insert the HCF Tray Assembly into the HCF. 5. Install the Rear Cover Kit to the HCF (See page 764).

Appendix H. 2000-Sheet Input Drawer Option 742

Right Hand Cover Open Switch


Asm-Index: 42-9, page 778.

1
hc2m041F

Figure 128. Right Hand Cover Open Switch Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.
Appendix H. 2000-Sheet Input Drawer Option 743

3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Right Hand Cover Open Switch (1). 5. Disconnect the P/J:S12.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S12. Attention: In the step below, install the Right Hand Cover Open Switch in the correct direction, otherwise the switch pins may be damaged. 2. Install the Right Hand Cover Open Switch. 3. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 744

Exit Sensor
Asm-Index: 42-10, page 778.

hc2m035F

Figure 129. Exit Sensor Removal

Appendix H. 2000-Sheet Input Drawer Option 745

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Disconnect the P/J:S8. 5. Remove the Exit Sensor (1).

Replacement
1. Install the Exit Sensor. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:S8. 3. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 746

Feed Roller Kit


Asm-Index: 42-28, page 778.
4 2
[2] [1]

2 1 3

[3]

5
hc2m030F

Figure 130. Feed Roller Kit Removal

Appendix H. 2000-Sheet Input Drawer Option 747

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).

4. 5. 6. 7. 8.

Disconnect the P/J:P1 and P/J:P2 connected to the Feed Roller Kit Harness (1). Remove the harness clamp securing the Feed Roller Kit Harness . Remove the two Feed Roller Kit Springs (2). Remove the hooks (3) (See 1 in the gure) securing the Feed Roller Kit (4). Remove the Right Hand Feed Roller Bracket (5) and the Left Hand Feed Roller Bracket (6) (See 2 in the gure)that lock the Feed Roller Kit. 9. Remove the Feed Roller Kit.

Replacement

Appendix H. 2000-Sheet Input Drawer Option 748

Attention: In the step below, check that the Feed Roller Kit properly pushes the Paper Level Sensor Actuator (See 3 in the gure). 1. Install the Feed Roller Kit. 2. Fix the Feed Roller Kit on the Right Hand Feed Roller Bracket and Left Hand Feed Roller Bracket and attach it to the frame in the Transport Unit Assembly. 3. Secure the Feed Roller Kit using the hooks. 4. Install the two Feed Roller Kit Springs. 5. Secure the Feed Roller Kit Harness with the harness clamp. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 6. Connect the P/J:P1 and P/J:P2. 7. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 749

Upper Limit Sensor


Asm-Index: 42-11, page 778.

1
hc2m036F

Figure 131. Upper Limit Sensor Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Feed Roller Kit (See page 747). 5. Remove the Upper Limit Sensor (1).
Appendix H. 2000-Sheet Input Drawer Option 750

6. Disconnect the P/J:S11.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S11. Attention: In the step below, install the Upper Limit Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Upper Limit Sensor. 3. Install the Feed Roller Kit (See page 747). 4. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 751

Paper Level Sensor


Asm-Index: 42-12, page 778.

hc2m037F

Figure 132. Paper Level Sensor Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Feed Roller Kit (See page 747). 5. Disconnect the P/J:10.
Appendix H. 2000-Sheet Input Drawer Option 752

6. Remove the Paper Level Sensor (1).

Replacement
1. Install the Paper Level Sensor. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:10. 3. Install the Feed Roller Kit (See page 747). 4. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 753

Feed Roller
Asm-Index: 42-14, page 778.

1
hc2m038F

Figure 133. Feed Roller Removal

Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Open the Rear Cover Kit. Remove the Feed Roller (1).
Appendix H. 2000-Sheet Input Drawer Option 754

Replacement
Reverse the Removal procedure.

Appendix H. 2000-Sheet Input Drawer Option 755

Tray Set Sensor 1,2


Asm-Index: 42-18 and 42-19, page 778.
1 2

hc2m039F

Figure 134. Tray Set Sensor 1,2 Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Tray Set Sensors 1 (1) and 2 (2).

Appendix H. 2000-Sheet Input Drawer Option 756

Note: Label the wires before removing them in the next step. 5. Disconnect the P/J:S6 and P/J :S7.

Replacement
Attention: In the step below, connect the P/Js as labeled, otherwise the system malfunctions. 1. Connect the P/J:S6 and P/J :S7. Attention: In the step below, install the Tray Set Sensors 1 and 2 in the correct direction, otherwise the sensor pins may be damaged. 2. Install the Tray Set Sensors 1 and 2. 3. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 757

Left Hand Cover Open Switch


Asm-Index: 42-20, page 778.

hc2m040F

Figure 135. Left Hand Cover Open Switch Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.

Appendix H. 2000-Sheet Input Drawer Option 758

3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Left Hand Cover Open Switch (1). 5. Disconnect the P/J:S9.

Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S9. Attention: In the step below, install the Left Hand Cover Open Switch in the correct direction, otherwise the switch pins may be damaged. 2. Install the Left Hand Cover Open Switch. 3. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 759

Transport Motor
Asm-Index: 42-21, page 778.

1
hc2m042F

Figure 136. Transport Motor Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 760

4. Disconnect the P/J:M2. 5. Remove the two screws (1) securing the Transport Motor (2). 6. Remove the Transport Motor.

Replacement
1. Secure the Transport Motor with the two screws . Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:M2. 3. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 761

LVPS
Asm-Index: 42-25, page 778.

1
hc2m043F

Figure 137. LVPS Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the HCF Tray Assembly (See page 721).
Appendix H. 2000-Sheet Input Drawer Option 762

4. 5. 6. 7.

Disconnect the P/J:XS1, XS2, XS3. Remove the screw (1) securing the ground wire coming from LVPS (2). Remove the four screws (3) securing the LVPS to the HCF. Remove LVPS.

Replacement
1. Secure LVPS to HCF with the four screws . 2. Secure LVPS ground wire with the screw. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 3. Connect the P/J:XS1, XS2, XS3. 4. Install the HCF Tray Assembly (See page 721).

Appendix H. 2000-Sheet Input Drawer Option 763

Rear Cover Kit


Asm-Index: 42-26, page 778.

hc2m031F

Figure 138. Rear Cover Kit Removal

Appendix H. 2000-Sheet Input Drawer Option 764

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Open the Rear Cover Kit (1). Note: In the step below, open the Rear Cover Kit halfway for easy removal. 4. Remove the Screw (2) holding the strap. 5. Remove the Rear Cover Kit.

Replacement
Reverse the Removal procedure.

Appendix H. 2000-Sheet Input Drawer Option 765

Transport Roll Kit


Asm-Index: 42-27, page 778.
1 1

3
[1]

5 4

hc2m033F

Figure 139. Transport Roll Kit Removal

Appendix H. 2000-Sheet Input Drawer Option 766

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. 5. 6. 7. 8. Remove Remove Remove Remove Remove the the the the the two E-rings (1). Gear (2). Left Hand Lock (3). Right Hand Lock (4). Transport Roll (5).

Replacement
1. Install the Transport Roll. 2. Install the Right Hand Lock. 3. Install the Left Hand Lock. Attention: In the step below, install the Gear so that the belt guard (See 1 in the gure) is to the outside. 4. Install the Gear. 5. Install the ve E-rings. 6. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 767

Flat Harness
Asm-Index: 42-29, page 778.

hc2m044F

Figure 140. Flat Harness Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 768

4. Disconnect all P/Js connected to the Flat Harness. 5. Remove all harness clamps securing the Flat Harness. 6. Disconnect the Flat Harness (1).

Replacement
1. Connect the Flat Harness. 2. Secure Flat Harness with the harness clamps. Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system will malfanction. 3. Connect the P/Js. 4. Install the Transport Unit Assembly (See page 741).

Appendix H. 2000-Sheet Input Drawer Option 769

Belt
Asm-Index: 42-22, page 778.

hc2m079F

Figure 141. Belt Removal

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 770

4. Remove the Transport Motor (See page 760). 5. Remove the Belt (1).

Replacement
Reverse the Removal procedure.

Appendix H. 2000-Sheet Input Drawer Option 771

Connector Kit
Asm-Index: 42-32, page 778.
[1] [2]

1 2

hc2m080F

Figure 142. Connector Kit Removal

Appendix H. 2000-Sheet Input Drawer Option 772

Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the HCF from the Base Engine (See page 717). 4. Disconnect the P/J:XS3 (See 1 in the gure). 5. Remove the two screws (1) securing the Connector Kit (2). 6. Disconnect the Connector Kit.

Replacement
1. Connect the Connector Kit. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:XS3. 3. Secure the Connector Kit with the two screws. 4. Install the Base Engine.

Appendix H. 2000-Sheet Input Drawer Option 773

Parts Catalog Assembly 40: 2000-Sheet Input Drawer I


1 2 3 4

1 (with 1A-18)

10 15 10 2. (PL42.1)
A

1A (PL41.1)
A

14

11
B

13 12 13 17 16 4 18 (with 16,17) 3 12 4 11

19 (with 4,5)

5 4 3 4
hc2m020F

Appendix H. 2000-Sheet Input Drawer Option 774

Table 97. Assembly 40: 2000-Sheet Input Drawer I


Asm Index 40 1 1A 2 3 6 7 8 10 11 12 13 14 and 15 18 16 17 19 4 5 A3, A4 B4 B2, B3 B1 A2, A3 C1 B2 B1 C1 B3, C3, C4 C2 A3 A2 A4 B2, C3 Grid Part Number 90H0720 NP NP NP 90H3469 NP NP NP 11L5342 90H3472 11L5343 11L5357 11L5344 90H3471 NP NP 90H3470 NP NP 2 2 2 2 1 1 1 1 1 4 1 1 1 1 2 Units High-capacity feeder I v High-capacity tray assembly (with 40-240-18) v High-capacity input drawer tray (same as 41-1) v v High-capacity feeder assembly (same as 42-1) v v Foot v v Wingnut v v Disk v v Disk v v HCF Screw v v Castor, Non-Locking v v HCF Locking Castor v v Drawer Castor v v E-ring and Clip v v Rails (with 40-16 and 40-17) v v v Rail v v v Rail v Hex Screw (with 40-4 and 40-5) v v Hex screw v v Hex key Description

Appendix H. 2000-Sheet Input Drawer Option 775

Assembly 41: 2000-Sheet Input Drawer Tray


1 2 3 4

19 (with 4,5)

1 (with 2-18) 13 2

4 17 16 5 15 12 14 14 14 6
B

17 18 7
B

14 18 5

11 10 9
C C

9 8
hc2m021F

Appendix H. 2000-Sheet Input Drawer Option 776

Table 98. Assembly 41: 2000-Sheet Input Drawer Tray


Asm Index 41 1 2 3 6 7 8 9 10 11 12 13 14 15 16 17 18 19 4 5 A4 A4 B4 B4 B1 C2 C2 C2 C2 B3 A3 B3 B2 A2 A1, B2 B1, B2 A2 A3, A4 B3 Grid Part Number 90H0720 NP NP NP NP 90H3474 NP NP 90H3475 90H3476 90H3477 NP 11L5346 11L5347 11L5348 11L5349 11L5350 90H3473 NP NP 1 1 1 1 1 1 2 1 1 1 1 4 1 1 2 2 1 2 2 Units High-capacity feeder tray v High-capacity input drawer tray (with 41-241-18) v v Bottom plate v v Right hand side plate v v Tray frame assembly v v Front cover v v Bearing v v Ring v v Elevator motor v v Paper low sensor v v Lower position sensor v v Left-hand side plate v v HCF Centering Format v v HCF Size Sensor v v HCF Harness v v HCF Holder v v HCF Clamp v HCF Key and Lock (with 41-4 and 41-5) v v Key v v Lock Description

Appendix H. 2000-Sheet Input Drawer Option 777

Assembly 42: 2000-Sheet Input Drawer II


1 2
1 (with 2-25,29-31,33-36) 32 (with 30,31) 4 25 31 31 5 34 33 21 23 35 24 22 10 34 4 4

3
26 (with 2,4,5,33)

A
30

B
20 29

27 (with 7,8,24,35, E-RINGx1,KL-CLIPx1)

B
6

13 19 18 12 36 9 11 14 17 15 16
hc2m022F

C
28 (with 14-17,36)

Appendix H. 2000-Sheet Input Drawer Option 778

Table 99. Assembly 42: 2000-Sheet Input Drawer II


Asm Index 42 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A2 A4 A3, A4 A3 B4 B3 C3 C2 B2 C2 C1 C1 C2 C2 C2 C1 C1 C1 B1 90H3485 90H3486 90H3487 90H3481 90H3482 90H3483 90H3484 NP NP Grid Part Number 90H0720 NP 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Units High-capacity feeder II v High-capacity feeder unit (with 42-242-25, 42-2942-31, and 42-3342-36) v v Rear cover (in kit P/N 90H3478) (see page 580) v v Spring (in kit P/N 90H3478) (see page 580) v v Paper chute (in kit P/N 90H3478) (see page 580) v v Feeder frame assembly v v Transport roll (in kit P/N 90H3479) (see page 580) v v Right-hand lock (in kit P/N 90H3479) (see page 580) v v Right-hand cover open switch v Sensor v v Upper limit sensor v v No paper sensor v v Frame v v Feed roller (in kit P/N 90H3480) (see page 580) v v Feed roller bracket (in kit P/N 90H3480) (see page 580) v v Right-hand feed roller bracket (in Kit P/N 90H3480) (see page 580) v v Left-hand feed roller bracket (in Kit P/N 90H3480) (see page 580) v v Tray set sensor 1 v v Tray set sensor 2 v v Left-hand cover open switch Description

Appendix H. 2000-Sheet Input Drawer Option 779

Table 99. Assembly 42: 2000-Sheet Input Drawer II (continued)


Asm Index 42 21 22 23 24 25 29 30 31 33 34 35 36 26 27 28 32 A1 B1 A1 B2 A2 B1 A3 A3 A4 A4, B4 B1 C2 A3 B2 C2 A2 90H3478 90H3479 90H3480 11L5352 1 11L5353 NP 06L9996 11L5351 Grid Part Number 90H0720 90H3488 90H3489 06L9750 1 1 1 1 1 1 1 1 1 2 1 1 1 1 Units High-capacity feeder II v v Transport motor v v Belt v v Gear v v Left-hand lock (in kit P/N 90H3479) (see page 580) v v Low voltage power supply v v HCF Flat Harness v v Connector harness (in kit P/N (see page 580) 11L5352) v v Screw v v Strap (in kit P/N 90H3478) (see page 580) v v HCF Clamp v v Spacer (in kit P/N 90H3479) (see page 580) v v Spring (in kit P/N 90H3480) (see page 580) Kit, rear cover (with 42-242-5, and 42-33) Kit, transport roll (with 42-7, 42-8, 42-24, 42-35, E-ring, and KL-Clip) Kit, feed roller (with 42-1442-17, and 42-36) (includes the feed motor) HCF Connector Kit (with 42-30 and 42-31) Description

Appendix H. 2000-Sheet Input Drawer Option 780

Glossary
The following terms are dened as they are used in this publication. If you do not nd the term you need, see the IBM Dictionary of Computing, New York, McGraw-Hill, 1994, or the IBM Dictionary of Printing. The following cross-references are used in this glossary: v Contrast with refers to a term that has an opposite meaning. v See refers to a preferred term with the same meaning. v See also refers to related terms.

A
A4-size paper. Paper that is 210 by 297 mm (8.3 x 11.7 in.). ac. Alternating current asm. Assembly attention notice. An attention warns of possible of damage to a program, device, system, or data. Attention notices are located throughout this publication. Attention notices are not translated. aux. Auxiliary

B
B5-size ISO paper.. Paper that is 176 mm by 250 mm (6.93 in. by 9.84 in.). B5-size JIS paper. Paper that is 182 mm by 257 mm (7.17 in. by 10.12 in.). BCR. Bias charge roller. BTR. Bias transfer roller.

Copyright IBM Corp. 1998

781

C
caution notice. A notice that calls attention to a condition that is potentially dangerous to people. CCW. Counterclockwise charge. The negative voltage that the HVPS applies to the surface of the drum. CM. Charge metering. continuity. A resistance reading of approximately zero (0) ohms. CR. Signal name for the charge voltage. CRU. Customer replaceable unit, such as the EP cartridge. CW. Clockwise

D
danger notice. A notice used to call attention to a condition that is potentially deadly or extremely dangerous. DB. Signal name for the developer bias voltage. dc. Direct current. default. An adjustment or setting that is set at the time of equipment manufacture. detack. Separating the toned sheet of paper from the surface of the drum after imaging. develop. The process when toner adheres to the latent image on the drum. developed image. The visible image on the drum after going through the development process. DPI. Dots per inch. The number of dots per inch printed by a laser printer. Each dot is either on or off, printed or not printed. See also (PPI). DRAM. Dynamic random-access memory.

Glossary 782

drum. The electrophotographic receptor. DTS. Signal name for the deteck saw voltage. duplex. Printing on both sides of a single sheet of paper.

E
EP. Electrophotographic. EP cartridge. The electrophotographic cartridge; sometimes referred to as the print cartridge, the toner cartridge, or as the CRU. error code. A unique set of letters and numbers that the printer displays to indicate that a problem exists in a specic area of the printer. ESD. Electrostatic discharge, which if discharged into the circuitry of an integrated circuit, can damage the circuit. exposure. The action of the laser beam striking and discharging select areas of the electrically charged surface of the drum.

F
FG. Frame ground. FU. Face-up. This abbreviation is used in some display messages. fuser. The printer subsystem that uses heat and pressure to permanently adhere, or fuse, a transferred toner image to a sheet of paper.

G
ground. Electrical ground.

Glossary 783

H
harness. A bundle of wires that form a single unit and are generally terminated with connectors at both ends. HCF. High capacity feeder, or 2000-Sheet Input Drawer HCI. High capacity input high. A signal voltage that is equal to or almost equal to the base voltage; such as +5 V dc or +24 V dc. See also low. HVPS. High voltage power supply.

I
image density. The relative darkness of the latent image on a sheet of paper. image development. Toner turning the latent image into a visible image. See also develop. image fusing. Using heat and pressure to permanently adhere a toned image to a sheet of paper. image transfer. Moving the developed image from the surface of the drum to the surface of a sheet of paper. interlock. Interlock switch. Used as a safety measure to remove voltage from circuits whenever a printer cover or the like is opened.

J
J. Jack. A female electrical connector. See also P and P/J.

K
KB. Kilobyte. 1 024 bytes. Kb. Kilobit. 1 024 bits.

Glossary 784

L
laser. Refers to the laser diode or to the laser beam. laser diode. Generates the laser beam that is used in the laser unit. laser beam path. The path that the laser beam takes, through lenses and mirrors, from the laser diode to the surface of the drum. latent image. The visible, electrical image remaining on the surface of the drum after exposure. LCD. Liquid crystal diode. LED. Light emitting diode. LEF. Long edge feed. legal-size paper. Paper that is 216 mm x 356 mm (8.5 in. x 14.0 in.). letter-size paper. Paper that is 216 mm x 279 mm (8.5 in. x 11.0 in.). low. A signal voltage that is signicantly lower than the base voltage. See also high. LVPS. Low voltage power supply.

M
MB. Megabyte. 1 024 000 bytes. Mb. Megabit. 1 024 000 bits. MBF. Multi-bypass lter. MCU. Machine control unit.

Glossary 785

N
NC. No connection. NOP. No paper. NVRAM. Non-volatile random access memory.

P
P. Plug A Male electrical connector.See also J and P/J. P/J. Plug/jack. A connected male (plug) and a female (jack). See also J and P. pel. See pixel. pixel (pel). (1) The smallest distinct element of a raster image or an image displayed on a monitor. (2) The elementary graphical cell that constitutes an image. (3) An element of a raster pattern or a point where a toned area on a photoconductor can appear. Pixels per inch (ppi). The number of pixels per linear inch. Unlike dots, which are bilevel entities, pixels can hold multiple levels of information. See also dots per inch. point. A unit of measurement for describing type sizes. There are 12 points to a pica; about 72 points to an inch. PPI. Pixels per inch. See also dots per inch (DPI). PPM. Pages per minute. print surface. The side of a sheet of paper that receives the printed image.

R
RTN. Return.

Glossary 786

S
SEF. Short edge feed. sensor. A device used to monitor a function or an operation, such as paper travel along the paper path. SG. Signal ground. signal name. A name given to a wire indicating the purpose of the wire and/or the voltage carried by that wire. SIMM. Single inline memory module. simplex. Generally means printing only on one side of a sheet of paper. See also duplex. SOS. Start of scan.

T
toggle. To switch between two states, such as on and off or up and down. toner. The dry ink that is used to create the visible image. Toner is stored in the EP cartridge. TR. Signal name for transfer current. transfer. Moving the toner image (developed image) from the surface of the drum to the surface of a sheet of paper.

Glossary 787

Index A
asm. locations duplex 362 env. feeder 362 printer 362 assembly locations 547

D
DANGER notice 6 defects, print quality detergent 588 diagnostic quick path diagnostics See getting started test prints, running paper path 251 disposal of materials documents, obtaining 34 28 25

grease 588 ground wires, locating 13 guides, obtaining from web

603

H
home page, Printing Systems Company 603

B
books, obtaining from web 603

8 from web

I
603 information, gathering 26 instructions, safety inspection 12 intermittent problems or errors 133

C
cable ESD (electrostatic discharge) 20 cable, ESD (electrostatic discharge) 20 CAUTION notice 7 cleaners and lubricants 588 clutch locations env. feeder 364 printer 364 code updates, obtaining from web 603 commonly used fasteners 588 parts 587 completing your task 36 components, electrical, location 364 connector locations printer 367 Copyright IBM Corp. 1998

E
electrical system safety 8 error codes and messages 000099 30, 31, 32 ESD procedures 20 30

L
laser safety 10 locations asms. duplex 362 env. feed 362 printer 362 clutches env. feeder 364 printer 364 connectors printer 367 electrical components 364 clutches, solenoids 364 miscellaneous 390 sensors 384

F
fasteners, common 588 fault isolation See diagnostic quick path 28 xes, obtaining from web 603

G
gathering information getting started 25 26

788

locations (continued) mechanical duplex 391 printer 390 mechanical components 390 PCBs duplex 380 env. feeder 380 printer 380 quick path 361 sensors duplex 384, 386 env. feeder 384, 386 printer 384, 386 solenoids env. feeder 364 printer 364 switches duplex 384, 386 env. feeder 384, 386 printer 384, 386 lubricants and cleaners 588

messages See error codes and messages miscellaneous, locations 390

29

N
Network Interface Card 541 NIC 541 notices electrostatic discharge (ESD) safety CAUTION 7 DANGER 6 description 6 safety precautions 8 disposal of materials 8 electrical safety 8 laser safety 10 ozone safety 11 toner safety 11 trademarks 22 20

O
oil 588 ozone safety 11

M
manuals, obtaining from web 603 marking actions as completed, safety inspection 13 mat, ESD 20 mechanical, locations 390 mechanical locations duplex 391 env. feeder 391 printer 390

parts catalog (continued) how to use (continued) grid 546 part number 546 units 547 parts catalog, how to use asm./index 546 parts location 547 PCB locations duplex 380 env. feeder 380 printer 380 print, paper path test 251 print quality defects 34 print quality problems 33 printer safety inspection 13 printer safety inspection 13 Printing Systems Company web page 603 problems intermittent 133 random 133 program xes, obtaining from web 603

P
paper path 251 test print 251 parts, common 587 parts catalog assembly locations 548 how to use description 547

Q
quick path, locations 361

R
random problems or errors 133 reference items, safety inspection routine tasks 35 13

Index 789

running test prints paper path 251

S
safety inspection 12 instructions 12 marking actions as completed printer 13 printer safety inspection 13 reference items 13 safety notices CAUTION 7 DANGER 6 description 6 safety precautions 8 disposal of materials 8 electrical safety 8 laser safety 10 ozone safety 11 toner safety 11 sensor locations duplex 384, 386 env. feeder 384, 386 printer 384, 386 sensors locations 384 SIMM 539 soap 588 solenoid locations env. feeder 364 printer 364 START of Call See getting started 25 13

status messages 239 switch locations duplex 384, 386 env. feeder 384, 386 printer 384, 386

T
test print, paper path 251 test prints, running 251 toner safety 11 trademarks 22 troubleshooting See getting started 25

U
updates (code), obtaining from web 603 utilities, obtaining from web 603

W
web page, Printing Systems Company 603 wrist band, ESD 20

Index 790

Printed in the United States of America on recycled paper containing 10% recovered post-consumer ber.

G544-5514-01