4322 service manuals

IBMI Infoprint 21

Service Guide

IBM

Note:Before using this information and the product it supports, be sure to read the general informationunder Notices (see “Notices and Safety Information” on page 19).

First Edition (April 2000)

This edition applies to G544-5702-00.

Requests for IBM publications should be made to your IBM representative or to the IBM branch office serving your locality. If yourequest publications from the address given below, your order will be delayed because publications are not stocked there. Many ofthe IBM Printing Systems Company publications are available from the web page listed below.

InternetVisit our home page at: http://www.ibm.com/printers

A Reader’s Comment Form is provided at the back of this publication. You may also send comments by fax to 1-800-524-1519, bye-mail to [email protected], or by regular mail to:

IBM Printing SystemsDepartment H7FE Building 003GInformation DevelopmentPO Box 1900Boulder CO USA 80301-9191

IBM may use or distribute whatever information you supply in any way it believes appropriate without incurring any obligation to you.

© Copyright International Business Machines Corporation 2000. All rights reserved.US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contract with IBM Corp.

Master Table of ContentsNotices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Danger Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Caution Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Attention Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Approved Power Cord and Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Connecting or Disconnecting a Communication Port, a Teleport, or an Attachment Connector . . . . . . . . . 24Disposal of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrostatic Discharge (ESD) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Extension Cords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Laser Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Ozone Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Servicing During an Electrical Storm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Toner Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Printer Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power-Receptacle Safety-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

About This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chapter 1. Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41MAP 003: End of Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

© Copyright IBM Corp. 2000 3

End of Diagnosing Problems and the Problem Remains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAP 010: Start MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operator Panel Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error Message with Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Coax/Twinax NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Ethernet / Token-Ring NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Electrical Noise / Intermittent Operation (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Excess Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Operator Panel, Controller and Power Problems (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Offset Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Duplex Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Envelope Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Tray 2 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Tray 3 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83MAP 002: Install New Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84MAP 006: Reseat Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86MAP 008: Install New Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87MAP 011: Tray x Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89MAP 012: (Aux/Env) Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97MAP 015: Tray x Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101MAP 016: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 109MAP 017: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 111MAP 031: Unload Paper From Main Output Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113MAP 035: Unload Paper From Offset Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115MAP 041: Install Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116MAP 042: Install Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118MAP 043: Install Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120MAP 049: Close Face-up Output Bin When Duplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Master Table of Contents 4

MAP 074: Close Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125MAP 075: Close Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129MAP 200: Wrong Paper Size - Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131MAP 201: Wrong Paper Size - Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132MAP 220: Paper Jam - Early Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134MAP 221: Paper Jam - Late Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148MAP 230: Paper Jam - Late Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162MAP 232: Paper Jam - Exit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167MAP 250: Paper Jam - Duplex Early Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171MAP 253: Paper Jam - Late Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173MAP 254: Paper Jam - Duplex On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175MAP 255: Paper Jam - Duplex Late Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177MAP 261: Paper Jam - Late Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179MAP 262: Paper Jam - Offset On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182MAP 272: Paper Jam - Exit On (Specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184MAP 275: Paper Jam - Early Exit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190MAP 276: Paper Jam - Exit On (Universal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192MAP 430: Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197MAP 451: Fan Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202MAP 454: Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204MAP 460: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206MAP 511: Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207MAP 623: Data Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209MAP 630: NVM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210MAP 631: NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211MAP 650: Service Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212MAP 651: Boot Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213MAP 652: Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214MAP 653: File Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216MAP 654: HW Error (MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217MAP 661: Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219


MAP 671: Disk Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220MAP 699: HW Error (Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221MAP 714: Duplex Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222MAP 772: ENV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223MAP 795: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225MAP 821: PS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226MAP 831: Controller Loop Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227MAP 851: IPDS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228MAP 852: IPDS Add Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229MAP 853: IPDS Low Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231MAP 854: IPDS Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232MAP 860: No CX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233MAP 861: No TX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234MAP 862: CX Key Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235MAP 872: Network Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236MAP 900: Background or Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237MAP 905: All Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240MAP 910: All Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242MAP 920: Damaged Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245MAP 930: Not Fused or Partially Fused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248MAP 935: Light Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250MAP 940: Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253MAP 941: Repeating Spots or Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256MAP 945: Residual or Ghost Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258MAP 950: Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260MAP 955: Spots on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263MAP 965: Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265MAP 970: Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268MAP 975: Voids on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270MAP 980: Horizontal Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273MAP 985: Vertical Band Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276


Chapter 2. Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Printer Power-On Sequence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Accessing Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

Printing the Service Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the CE Laptop PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Chapter 3. Wiring and Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297Master Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . 299Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and to Fan Asm and Front Cover

Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and Fuser Asm . . . . . . . . . . . . . . 301Pin-Out Diagram D: MCU PCB to Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear Cover Interlock Switch . . . . . . . . . 303Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to Paper Low Photo Sensor and Lift

Control Photo Sensor, Pick Clutch, Feed Clutch, and Tray Lift Motor . . . . . . . . . . . . . . . . . . . . 304Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor, and Main Motor . . . . . . . . . 305Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor, Aux Pick-up Solenoid,

Registration Sensor, Registration Clutch, Toner Sensor, and Envelope PCB. . . . . . . . . . . . . . . . . 306Pin-Out Diagram J: MCU PCB to Laser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Chapter 4. Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Major Assemblies, Components, and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312PCBs (Printed Circuit Boards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313


Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315

Chapter 5. Removals and Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Text and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3255v DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Aux Drive Gear Shaft and Aux Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Aux No Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Aux No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Aux Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Aux Pick Up Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Aux Pick Up Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Aux Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Aux Retard Pad Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Aux Tray Bottom Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Bearing and Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Duplex Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Duplex Connector Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352


Duplex Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353Duplex Face Up Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Duplex Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Duplex Motor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Duplex Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357Duplex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Duplex Roll Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359Duplex Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Duplex Upper Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361ENV Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362ENV Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363ENV Clutch (Electric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364ENV Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366ENV Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367ENV Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368ENV Large Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369ENV No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370ENV No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371ENV Retard Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372ENV Roll Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373ENV Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375ENV Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376ENV Tray Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377ENV Tray Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384Face-Up Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385


Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389Feed Tray Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392Front Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398Fuser Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Harness (J27, J11, J262 - J271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401Harness (J34-P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Left Handle Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410Lift Control Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415Metal Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Middle Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419


Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420Offset Direction Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422Offset Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423Offset Exit Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424Offset Exit Bin Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Offset Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428Offset Inner Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Offset Inner Chute Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Offset Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Offset Mechanism Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Offset PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Offset Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435Offset Tray Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437Option Chute Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440Option Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441Option Gear Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Option Harness (J52-J521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443Option Harness (J53-531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446Option Lift Control Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447Option No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449Option Paper Low Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450Option Paper Size Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451


Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Option Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459Option Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460Option Top Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463Paper Size Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464Paper Size Housing Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Paper Sizing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466PCB Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Rear Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476Rear Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485Rubber Registration Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Rubber Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489


Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Tray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494Tray Lift Motor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498Tray Retard Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502

Chapter 6. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504Using the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Approved Cleaners and Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519Assembly 4: 550-Sheet Tray Asm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521Assembly 5: 550-Sheet Tray Asm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523Assembly 6: Paper Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526Assembly 7: Aux Tray Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530Assembly 8: P/H Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533Assembly 9: Chute Transfer and Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536Assembly 10: Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538Assembly 11: Drive and Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541Assembly 12: Frame and Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543Assembly 13: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546Assembly 14: Optional Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549Assembly 15: Optional Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552Assembly 16: Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556


Assembly 17: Envelope Feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559Assembly 18: Duplex 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562Assembly 19: Duplex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564Assembly 20: Offset Output Bin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Assembly 21: Offset Output Bin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569

Parts Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5735 V DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Actuator And Support Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Aux Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Drive Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bearing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Coax NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Compact Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Face-up Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env No-Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Ethernet NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581


Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Chute Pinch Roll Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Font Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 120 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 230 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Harness (AC - J285) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J1 - J101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J21 - J211, J212, J213) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J22 - J223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J23 - J231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J25 - J251) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J26 - J261) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J27, J11, J262-J271). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591


Harness (J28 - J281) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J282 - J9, J288 - J9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J31 - J311). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J33 - J331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J34 - J341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J34 - P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J4 - Operator Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J42 - J421) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J43 - J432, J433) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J45 - J451) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J66 - J661, J662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596IBM AFP/IPDS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 120V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 230V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Memory DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Exit Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601


Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Top Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Rear Cover Asm (With Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Asm (Without Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Token Ring NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612


Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Twinax NIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614

Chapter 7. Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615Periodically Replaced Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615

Appendix A. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616

Appendix B. Drivers, Technical Support, and Warranty Information . . . . . . . . . . . . . . . . . . . . . 617Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Dealer Warranty Claim Center (DWCC), U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

Maintenance (Service) Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619

Appendix C. Parts Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620


Notices and Safety Information

Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Danger Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Caution Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Other Caution Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Attention Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Approved Power Cord and Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Connecting or Disconnecting a Communication Port, a Teleport, or an Attachment Connector . . . . . . . . . 24Disposal of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrostatic Discharge (ESD) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Using the ESD Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Extension Cords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Laser Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Ozone Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Servicing During an Electrical Storm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Toner Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Reference Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Printer Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Safety Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Power-Receptacle Safety-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34


References in this publication to IBM products, programs or services do not imply that IBM intends to make theseavailable in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service isnot intended to state or imply that only IBM’s product, program, or service may be used. Any functionallyequivalent product, program, or service that does not infringe any of IBM’s intellectual property rights may be usedinstead of the IBM product. Evaluation and verification of operation in conjunction with other products, exceptthose expressly designated by IBM, is the user’s responsibility.

Any performance data contained in this document was obtained in a controlled environment based on the use ofspecific data. The results that may be obtained in other operating environments may vary significantly. Users ofthis document should verify the applicable data in their specific environment. Therefore, such data does notconstitute a performance guarantee or warranty.

IBM may have patents or pending patent applications covering subject matter in this document. The furnishing ofthis document does not give you any license to these patents. You can send license inquiries, in writing, to theIBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.

Notices and Safety Information 20

Safety NoticesThere are two types of safety notices: Danger and Caution.

Danger Hazard LevelThe word Danger indicates the presence of a hazard that has the potential of causing death or serious personalinjury.

DANGER notices are numbered <1-1>, <1-2>, and so forth where they appear in the text of this manual. Use thenotice number to locate the national language translation of that notice in the IBM Infoprint 20/21/32/40: Warranty,Communication Statements, and Safety Information.Example of a Danger notice:


Caution Hazard LevelThe word Caution indicates the presence of a hazard that has the potential of causing moderate or minorpersonal injury.

CAUTION notices are numbered <2-1>, <2-2>, and so forth where they appear in the text of this manual. Use thenotice number to locate the national language translation of that notice in the IBM Infoprint 20/21/32/40: Warranty,Communication Statements, and Safety Information.Example of a Caution notice:

! CAUTION:

<2-23> Pinch hazards exist in this area. hcsf

0223

Other Caution Symbols UsedOther Caution symbols used in this manual include the following:

Laser Safety High Temperature Heavy Weight


Attention NoticesThe word Attention calls attention to the possibility of damage to a program, device, system, or data.

Attention notices are not numbered, or translated in the IBM Infoprint 20/21/32/40: Warranty, CommunicationStatements, and Safety Information.Example of an Attention notice:

Attention: This is an ESD sensitive device (see “Electrostatic Discharge (ESD) Procedures” on page 26).


Safety Precautions

Approved Power Cord and Receptacle

Connecting or Disconnecting a Communication Port, a Teleport, or anAttachment Connector


Disposal of Materials

Electrical SafetyThis 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 nationaltesting laboratory indicates that the product is designed and manufactured in accordance with nationalrequirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in designand manufacture. Remember, however, that this product operates under conditions of high electrical potentialsand heat generation, both of which are functionally necessary.


Electrostatic Discharge (ESD) ProceduresRead the following electrostatic discharge (ESD) information because, if discharged into the circuitry of anintegrated circuit, static electricity can damage the circuit.

The following Attention notice in the text of this book warns of possible damage caused by ESD.

Attention:

This is an ESD sensitive area.

Follow these guidelines to prevent damage to ESD-sensitive components:v Make the fewest possible movements to minimize static electricity. Static electricity is more likely in a low

humidity environment.v Keep an ESD-sensitive part in its original shipping container, usually a protective bag, until you are ready to

install it.v Touch the metal frame of the printer or assembly to discharge static electricity in your body just before touching

the ESD-sensitive part.v 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.v 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, put it into the ESD protective wrapper inwhich it was shipped.

v Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working with connectors.v Prevent ESD-sensitive parts from being touched by other persons.

Continue to “Using the ESD Kit” on page 27.


Using the ESD KitTo safely discharge all static electricity, use the ESD kit following the guidelines under “Electrostatic Discharge(ESD) Procedures” on page 26.v Turn off the printer before you put on the ESD wrist band.v Connect the wrist band to an unpainted, frame-ground point of the printer.v Remove the ESD wrist band when working on any part of the printer that has power turned on.v Do not put the ESD mat near any electrical circuit that has power turned on. The internal resistance (1

megohm) in the ESD cable limits the current if it touches a high voltage.v 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 highresistance in the ESD cable is bypassed, which causes the ESD mat not to work as expected.

Extension Cords

Fire SafetyBecause the paper and toner used in the printer can burn, you should take normal precautions to prevent fire.These precautions include common sense measures, such as keeping potentially combustible materials (forexample, curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limitingunattended operation, and having trained personnel available and assigned to the printer.


Laser Safety

CAUTION:<2-21> Do not disassemble or attempt to adjust the laser unit. Do not attempt to operate the laser outside of theprinter.

This printer complies with the performance standards set the by U.S. Food and Drug Administration for a Class 1Laser Product. This means that the printer belongs to a class of laser products that does not produce hazardouslaser radiation in a customer access area. This classification was accomplished by providing the necessaryprotective housing and scanning safeguard 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 trainedservice 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.

Ozone SafetyAn infinitesimal 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 referencevalue set by Underwriters Laboratory (UL) at the time it is shipped from the factory.


Servicing During an Electrical Storm

Toner Safety

! CAUTION:

<2-38> To vacuum toner, use only a vacuum cleaner that IBM hasapproved for use with toner.

hcsf

0238

Toner is a non-poisonous substance composed of minute, plastic components. If toner adheres to your skin or toyour clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hot water, thetoner will gel and become difficult to remove. Avoid letting toner come into contact with vinyl. The plasticizers invinyl can also plasticize some toners.


Safety InspectionSee “Danger Hazard Level” on page 21 and “Caution Hazard Level” on page 22 for an explanation of Danger andCaution notices.

InstructionsPerform this safety inspection before performing any of the following tasks:v Accept a machine for service agreementv Provide per-call servicev Relocate a machinev Review changes or attachments on any IBM machine that is leased, on service agreement, or on per-call

service

Ensure that you correct unsafe conditions before you continue.

Possible safety hazards are:v Electrical —An electrically charged frame, or exposed wires or connections, can cause serious electrical shock.v Mechanical —A missing safety cover or shield is hazardous. Moving parts, such as gears, shaft, and pulleys

are hazardous.v Chemical —Use only approved cleaning agents. Do not use other solvents or chemicals.

Reference ItemsYou will need the following items:v A copy of the machine EC historyv Electrical Safety for IBM Customer Engineers, S229-8124


Printer Safety Inspection

1. Perform the “Power-Receptacle Safety-Check” on page 34.2. Ensure that the correct power cord is used.3. Ensure that all attaching cables are disconnected from the printer.4. Inspect the power cord for wear or damage.5. Ensure that the machine is steady.6. Remove all covers and access panels (see Covers under ″Removals and Replacements″).7. Inspect the covers and access panels for damage.8. Ensure that all warning labels are in place.9. If you are placing this printer on service contract with IBM, check for changes not made by IBM. If you find

changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBM branchoffice. Complete the form and return it to the branch office.

10. Ensure that all ground connectors are correctly connected (see “Safety Ground” on page 33).11. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. The

reading must not exceed 0.1 ohms.12. Perform a visual inspection of all cables, connections, and plugs for worn or damaged wiring.


13. Check for signs of contamination, corrosion, smoke, or burning. If there are signs of smoke or burning, checkthe Maintenance Agreement Qualification (MAQ) form for the correct repair procedure, if needed.

14. Install all covers and access panels that were removed.


Safety Ground

HA

K30

8Figure 1. Safety Ground


Power-Receptacle Safety-CheckSee Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and proceduresbefore performing any of the following tasks. ( Electrical Safety for IBM Customer Engineers, S229-8124 may notbe applicable for other countries):

v Checking ac voltage at the power receptaclev 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.Table 1. Nominal Power Receptacle AC Voltage (110–120 V AC, 50–60 Hertz)

Machine Rating(50–60 Hertz) Minimum Voltage Maximum Voltage

100-127 V ac 90 V ac 140 V ac

220–240 V ac 200 V ac 264 V ac

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


About This Book

This book describes how to diagnose and repair the Infoprint 21.

Related PublicationsTo obtain additional copies of this book or of any related publication, contact your IBM service representative, yourauthorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755.

For related topics not covered in this book, refer to the list below.v IBM Infoprint 20/21/32/40: Warranty, Communication Statements, and Safety Information, G544-5523v IBM Infoprint Printers: Service CDROM, GK2T-9300v Infoprint 21 User’s Guide, G544-5701v Infoprint 21 Quick Reference Card, G544-5700v Infoprint 21 Setup Poster, S544-5699v Ethernet and Token Ring Configuration Guide, S544-5711v Twinax and Coax Configuration Guide, S544-5712v IPDS and SCS Technical Reference, S544-5312


TrademarksThe following terms are trademarks of the IBM Corporation in the United States or other countries or both:

IBM®

Infoprint™

Microsoft, Windows, Windows NT, and the Windows logo are trademarks of Microsoft Corporation in the UnitedStates and/or other countries.

Other company, product, or service names may be the trademarks or service marks of others.

About This Book 36

Chapter 1. Diagnosing Problems

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41MAP 003: End of Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

End of Diagnosing Problems and the Problem Remains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAP 010: Start MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Operator Panel Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error Message with Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Coax/Twinax NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Ethernet / Token-Ring NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Electrical Noise / Intermittent Operation (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Excess Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Operator Panel, Controller and Power Problems (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Offset Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Duplex Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Envelope Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Tray 2 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Tray 3 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83MAP 002: Install New Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84MAP 006: Reseat Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86MAP 008: Install New Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87MAP 011: Tray x Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89MAP 012: (Aux/Env) Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97MAP 015: Tray x Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101MAP 016: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 109MAP 017: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 111MAP 031: Unload Paper From Main Output Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113


MAP 035: Unload Paper From Offset Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115MAP 041: Install Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116MAP 042: Install Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118MAP 043: Install Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120MAP 049: Close Face-up Output Bin When Duplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122MAP 074: Close Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125MAP 075: Close Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129MAP 200: Wrong Paper Size - Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131MAP 201: Wrong Paper Size - Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132MAP 220: Paper Jam - Early Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134MAP 221: Paper Jam - Late Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148MAP 230: Paper Jam - Late Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162MAP 232: Paper Jam - Exit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167MAP 250: Paper Jam - Duplex Early Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171MAP 253: Paper Jam - Late Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173MAP 254: Paper Jam - Duplex On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175MAP 255: Paper Jam - Duplex Late Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177MAP 261: Paper Jam - Late Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179MAP 262: Paper Jam - Offset On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182MAP 272: Paper Jam - Exit On (Specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184MAP 275: Paper Jam - Early Exit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190MAP 276: Paper Jam - Exit On (Universal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192MAP 430: Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197MAP 451: Fan Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202MAP 454: Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204MAP 460: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206MAP 511: Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207MAP 623: Data Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209MAP 630: NVM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210MAP 631: NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211MAP 650: Service Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

Chapter 1. Diagnosing Problems 38

MAP 651: Boot Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213MAP 652: Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214MAP 653: File Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216MAP 654: HW Error (MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217MAP 661: Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219MAP 671: Disk Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220MAP 699: HW Error (Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221MAP 714: Duplex Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222MAP 772: ENV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223MAP 795: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225MAP 821: PS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226MAP 831: Controller Loop Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227MAP 851: IPDS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228MAP 852: IPDS Add Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229MAP 853: IPDS Low Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231MAP 854: IPDS Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232MAP 860: No CX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233MAP 861: No TX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234MAP 862: CX Key Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235MAP 872: Network Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236MAP 900: Background or Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237MAP 905: All Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240MAP 910: All Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242MAP 920: Damaged Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245MAP 930: Not Fused or Partially Fused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248MAP 935: Light Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250MAP 940: Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253MAP 941: Repeating Spots or Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256MAP 945: Residual or Ghost Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258MAP 950: Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260MAP 955: Spots on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263


MAP 965: Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265MAP 970: Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268MAP 975: Voids on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270MAP 980: Horizontal Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273MAP 985: Vertical Band Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276


IntroductionThis chapter helps you define the problem and begin problem isolation. All problem definition and resolutionbegins in “MAP 010: Start MAP” on page 44. After a problem has been fixed go to “MAP 003: End of Call” onpage 42 to perform the defined procedures prior to completing the call.

If the suggested diagnostics do not resolve the problem, return to “MAP 010: Start MAP” on page 44 and definethe problem again or call for technical support. See “Appendix B. Drivers, Technical Support, and WarrantyInformation” on page 617.

This chapter contains only MAPs (Maintenance Analysis Procedures) for problem diagnosis. Some of theseprocedures require other actions such as printing a Service Page or other checks. “Chapter 3. Wiring and Pin-OutDiagrams” on page 297 contains information on printing test prints and performing checks and tests.


MAP 003: End of CallUse the following procedure to complete all service calls on the Infoprint 21.1. Ensure the following:v All internal cables and connectors are properly connected.v All covers, doors, panels and paper trays are in place.v Any workstation or network cable is connected.v All power cords are connected.

2. Power on the printer and ensure that the printer performs the correct power-on sequence. See “PrinterPower-On Sequence Check” on page 279.

3. Print a Printer Configuration page to ensure high-quality output. See “Printing the Service Page” on page 295.Look at the Page Count item located on the Printer Configuration page. You may need this count for youractivity reporting.

4. Have the operator print a job to ensure the printer is working correctly.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 the printer operation to the operator.


End of Diagnosing Problems and the Problem RemainsIf the printer has not been fixed using the MAP procedures that you were directed to perform, return to “MAP 010:Start MAP” on page 44. Ensure that you have correctly interpreted the available information and define theproblem again.

Review all MAPs that you were directed to. If you suspect an intermittent problem, check the following:v All connectors and wiring associated with the suspected FRUs.v All frame grounds and ground connectors.v If you suspect a consumable (CRU), supplies or supplies storage problem (environmental conditions such as

temperature, humidity, or ventilation), refer to the IBM Infoprint 21 User’s Guide.

Refer to the list of Suspect FRUs at the beginning of the MAP and repair/replace any remaining FRUs that youhave not already replaced. After each replacement, print a Printer Configuration page to determine if the problemhas been fixed. If you have replaced a part that did not correct the problem, reinstall the original part beforecontinuing.

If a fix has not been found for the problem, contact your next level of support. See “Appendix B. Drivers, TechnicalSupport, and Warranty Information” on page 617.


MAP 010: Start MAP

Defining the ProblemUse the following suggestions to gather the information to accurately define the printer problem, and then go to“Solving the Problem” on page 46.1. Discuss the problem with the operator. Note information such as error messages, other symptoms (such as

print quality), what happened, what type of print job, and other recent problems or changes. Review the printerhistory with the operator and obtain or print a Printer Configuration page and an Error Log (see “Printing theService Page” on page 295).

2. Power on the printer. The printer performs start-up diagnostic routines that check the printer controller and theprinter. Most printer failures that occur during this start-up diagnostic portion of the initialization process, resultin either an error code or a message posted immediately on the operator panel. See “Printer Power-OnSequence Check” on page 279 for the correct sequence of events when the printer is powered on.

3. Observe the display on the operator panel.

Note: All Operator Panel messages referenced in this service guide are in English. If your Operator Panel hasbeen set to a language other than English, you may want to change the language to English by usingthe Language Menu . See the Infoprint 21 User’s Guide.

v Is information correctly displayed?v Is the display blank after power is switched on?v Does INFOPRINT 21 INITIALIZING display?v Does READY display?v Do you have an error code or message?

4. Try to duplicate the failure by printing a Printer Configuration page (see “Printing the Service Page” onpage 295) or by printing the customer job and noting the following:v Printer fails to print a test print when not connected to a workstation or a network.v Printer fails when connected to a workstation or network.v Printer prints, but the paper jams.


v Printer prints, but has poor quality.5. See “Solving the Problem” on page 46.


Solving the ProblemUsing the problem information that you have gathered (see “Defining the Problem” on page 44, go to Table 2.Select the Symptom or the Indication that best describes the printer problem, and then go to the suggested itemto further isolate the failure. Upon completing the problem diagnosis and repair, go to “MAP 003: End of Call” onpage 42 to complete the call.Table 2. Diagnostic Quick Path

Symptom Indication Go To...

Operator PanelProblem Indications

Solid black rectangle boxes always on “Operator Panel, Controller and Power Problems(Printer)” on page 73

Message with error code “Error Message with Error Code” on page 55

Message without error code “Operator Panel Messages” on page 48

Blank, push button or other display problem “Operator Panel, Controller and Power Problems(Printer)” on page 73

Print Quality Print quality problem Table 5 on page 59

Feature Problems Ethernet or token ring problems “Ethernet / Token-Ring NIC Printing Problem(Printer)” on page 63

Twinax or coax problems “Coax/Twinax NIC Printing Problem (Printer)” onpage 60

Duplex not working / not recognized “MAP 714: Duplex Error” on page 222

Envelope Feeder not working / not recognized “MAP 772: ENV Error” on page 223

Offset Output Bin not working / not recognized “MAP 795: Offset Error” on page 225

Tray 2 not working / not recognized “Tray 2 Not Recognized (Printer)” on page 81

Tray 3 not working / not recognized “Tray 3 Not Recognized (Printer)” on page 83

Memory problems (Memory error) “MAP 652: Memory Error” on page 214

Table continues on p. 47.


Table 2. Diagnostic Quick Path (continued)

Symptom Indication Go To...

Other Problems Power “Operator Panel, Controller and Power Problems(Printer)” on page 73

Excessive Noise “Excess Noise” on page 69

Electrical Noise, Intermittent Operation (Printer) “Electrical Noise / Intermittent Operation (Printer)” onpage 66


Operator Panel MessagesThe Operator Panel messages in the following table are listed in alphabetical order in English. If your OperatorPanel has been set to a language other than English you may want to change the language to English by usingthe Language Menu (see Infoprint 21 User’s Guide).

Select the message that was displayed in the Operator Panel display area, then perform the specified action.Table 3. Operator Panel Messages

Message Meaning Action

CANCEL PRINT JOB? / +YES, - NO

A job was printing when the printer went offline. Thismessage allows the operator to cancel or pause the job.

Press the + key to cancel the job, press the− key to pause the job and take the printeroffline.

CANCELING JOB The printer is canceling a PCL or PostScript job. None required.

CLEAN DISK? / + YES, -NO

You selected the CLEAN DISK action on the ResetMenu.

Press the + key to clean the hard drive.Cleaning the hard drive removes all filesother than those that contain IPDS fonts.Press the − key to continue withoutformatting.

CLEAN CANCELED Cleaning was canceled. None required.

COLD RESET / PLEASEWAIT

The printer is powering up and resetting all menu valuesto the factory defaults.

None required; however, you need torestore any unique settings for the printer(such as default trays or bins).

CX/TX CANCEL SENT A coax or twinax cancel request was sent to the host. None required.

CX/TX INVALID KEY An invalid coax or twinax key was pressed. None required.

DEFAULT A4 / PLEASEWAIT

The printer is powering up and setting the A4 papergroup as the default.

None required.

DEFAULT LETTER /PLEASE WAIT

The printer is powering up and setting the LETTERpaper group as the default.

None required.

FORMAT COMPLETE Formatting is finished. None required.


Table 3. Operator Panel Messages (continued)


FORMAT FLASH? / + YES,- NO

You selected the FORMAT FLASH action on the ResetMenu.

Press the + key to format the ResourceFlash Memory Module. Press the − key tocontinue without formatting.

FORMAT IGNORED Formatting was canceled. None required.

FORMATTING The printer is formatting the Resource Flash MemoryModule.

None required. Do not power off untilformatting is complete.

INITIALIZING / PLEASEWAIT

The printer is warming up. None required.

IR SENT TO HOST /PRESS ENTER

An interrupt request was sent to the host. Press Enter to continue.

JOB QUEUED An informational page has been submitted from the TestMenu (for example, a configuration page or a fonts list).

None required.

LOAD <dimensions><media type> IN <tray>CUSTOM SIZE NOTDEFINED

A job has requested an unknown paper size. Themessage identifies the media dimensions, media type,and tray, that the print job requested.

Do one of the following:v To print the job on the requested tray,

regardless of what media is in the tray,press Enter .

v To define a custom form that matches thejob, do the following:1. Use the Custom Forms Menu to

define the form.2. Use the Paper Menu to set the tray

size to the new form and the traytype to requested type.




LOAD <size> <dimensions><media type> in <tray>

Someone changed the paper in a tray after a job beganformatting. The specified tray no longer contains themedia requested by a job that has already beenformatted. The message identifies the media dimensions(for custom size jobs), the media type, and the tray thatthe print job requested.

Do one of the following:v Reload the tray with the required media.v To print the job from another tray that

contains the correct size media, althoughnot necessarily the correct type, pressEnter .

v Press the Online key and, whenprompted, cancel the job.

LOAD <size> <dimensions><media type> in <tray> /PRESS ENTER TO USEDEFAULT TRAY

The specified tray does not contain the media requestedby a job. The message identifies the media dimensions(for custom size jobs), the media type, and the tray thatthe print job requested.

Do one of the following:v Reload the tray with the required media.

If you reload the auxiliary tray or theenvelope feeder, the printer will set theAUXSIZE or ENVSIZE values to the sizeof the new media.

v To reformat and print the job using thespecified tray, regardless of the media itcontains, press Enter .

v Press the Online key and, whenprompted, cancel the job.

MANUALLY FEED <size><dimensions> <type> INAUX TRAY

Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and the printer is waiting for you to pressthe Enter key to print the next page. The messageidentifies the required media dimensions (for custom sizejobs), the media size (as defined by the AUXSIZE item inthe Paper Menu), and the media type (as defined by theAUX TYPE item in the Paper Menu).

Load the requested media in the auxiliarytray and press the Enter key to print thenext page.




MANUALLY FEED<dimensions> <type> INAUX TRAY CUSTOM SIZENOT DEFINED

Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and a job has requested an unknownpaper size. The message identifies the mediadimensions and the media type that the print jobrequested.

Do one of the following:v To print the job on the requested tray,

regardless of what media is in the tray,press Enter .

v To define a custom form that matches thejob, do the following:1. Use the Custom Forms Menu to

define the form.2. Use the Paper Menu to set the tray

size to the new form and the traytype to requested type.

MANUAL FEED <size><type> IN AUX TRAY

Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and the printer is waiting for you to pressthe Enter key to print the next page.

Load the requested media in the auxiliarytray and press the Enter key to print thenext page.

MENUS LOCKED /PLEASE WAIT

The system administrator has locked the menu. You canview menu settings but you cannot change them.

None required.

MENUS UNLOCKED /PLEASE WAIT

The system administrator has unlocked the menus. None required. Wait until the messageclears to change menu settings.

NEW VALUES AT NEXTBOUNDARY

You have changed a menu item, but the new value willnot take effect until the next “job boundary”. Differentdata streams, in particular SCS, define job boundaries indifferent ways, so it may take awhile for the new value totake effect.

None required. If problems occur, makesure you change menu values only when nojobs are printing (the printer is in Readystate).

NO CX HOST SYNC /PRESS ENTER

There is no host synchronization over the coax port. Press Enter to continue.

NO TX HOST SYNC /PRESS ENTER

There is no host synchronization over the twinax port. Press Enter to continue.




OFFLINE The printer is offline. Press the Online key to make the printeractive.

OFFLINE IN PROGRESS The printer is going offline. None required.

ONLINE IN PROGRESS The printer is going online. None required.

ONLINE HEX PRINT The printer is performing a hexadecimal dump. None required.

PA1 KEY SENT A PA1 request was sent to the host over the coaxinterface.

None required.

PA2 KEY SENT A PA2 request was sent to the host over the coaxinterface.

None required.

PA KEY REQUESTED /PRESS ENTER

A PA1 or PA2 request was sent to the host over the coaxinterface.

Press Enter to continue.

POWER SAVE ON The printer is in power-saving mode and has temporarilyshut off power to certain of its components. Power will berestored as soon as a job is submitted.

None required.

PRESS ENTER TO PRINTPARTIAL PAGE

A PCL job has left the last page of a job in the printerbuffer.

Press Enter to print the page.

PRESS ONLINE TO PRINT An informational page (for example, a printerconfiguration page) has been queued for printing,however, the printer is offline.

Press Online to put the printer online andprint the job.

PRINTING jobname The printer is printing a job. None required.

PRINTING IPDS / FROMTRAY x

The printer is printing an IPDS job using paper from thespecified tray.

None required.

PRINTING IPDS / COPY xof x

The printer is printing an IPDS job. None required.

PRINTING PCL / FROMTRAY x

The printer is printing a PCL job using paper from thespecified tray.

None required.




PRINTING PCL / COPY x ofx

The printer is printing a PCL job. None required.

PRINTING PS / FROMTRAY x

The printer is printing a PostScript or PDF job usingpaper from the specified tray.

None required.

PRINTING PS / COPY x ofx

The printer is printing a PostScript or PDF job. None required.

PROCESSING jobname The printer is processing a job. None required.

PROCESSING IPDS The printer is processing an IPDS job. None required.

PROCESSING PCL The printer is processing a PCL job. None required.

PROCESSING PS The printer is processing an PostScript or PDF job. None required.

READ ONLY VALUE You cannot change the menu value displayed on theoperator panel.

None required.

READY The printer is ready to receive data. None required.

REBOOT THE PRINTER? /+ YES, - NO

You have changed a menu item that cannot take effectuntil the printer is rebooted. This message lets you verifythat you want to reboot the printer.

Press the + key to reboot. Press − tocontinue operating with the old values untilthe next time the printer is rebooted.

REBOOTING / PLEASEWAIT

The printer is rebooting. None required.

RESET COMPLETE The toner or fuser counter has been reset to 0. None required.

REQUEST RECEIVED A user powered-on the printer while holding down keyson the operator panel. For example, holding down theOnline key while powering on the printer resets printervalues to their factory defaults.

The printer recognizes the special requestand the user can let go of the keys.

RESET COUNTER? / +YES, - NO

You asked to reset the toner counter or the fusercounter.

Press the + to reset the counter. Press the− key to cancel the reset.




RESET IGNORED A request to reset the toner or fuser counter wascanceled; the counter has not been reset.

None required.

RESET TO FACTORYDEFAULTS? / + YES, - NO

You asked to reset printer values to the factory defaults. Press the + key to reset the values. Pressthe − key to continue without resetting.

RESETTING... The toner or fuser counters are being reset. None required.

RESTORING DEFAULTS The printer is restoring the factory defaults for the printeror network interface card.

None required.

WARMING UP The printer is warming up. When it is warm, it displaysthe READY message.

None required. If the message seems toappear too frequently, change the value forthe power-saving mode to a larger value.


Error Message with Error CodeThe Operator Panel messages in the following table are listed in numerical order by error code. Note thatmessages contain two lines. The error code appears on the second line. Find the error code that was displayedon the Operator Panel, then go to the suggested MAP to further isolate the failure.Table 4. Error Message with Error Code

Error Code Go To...

002 TONER LOW / INSTALL NEW TONER CARTRIDGE “MAP 002: Install New Toner Cartridge” on page 84

006 TONER ERROR / RESEAT TONER CARTRIDGE “MAP 006: Reseat Toner Cartridge” on page 86

011 TRAY <tray> EMPTY / LOAD <size> <dimensions> <mediatype>

“MAP 011: Tray x Empty” on page 89

012 AUX/ENV EMPTY / LOAD <size> <dimensions> <mediatype>

“MAP 012: (Aux/Env) Empty” on page 97

016 CHECK TRAY <tray> / ADJUST GUIDES FOR PAPER SIZEOR SET SIZE IN MENU

“MAP 016: Adjust Guides For Paper Size Or Set Size In Menu”on page 109

031 OUTPUT FULL / UNLOAD PAPER FROM MAIN BIN “MAP 031: Unload Paper From Main Output Bin” on page 113

035 OUTPUT FULL / UNLOAD PAPER FROM OFFSET BIN “MAP 035: Unload Paper From Offset Bin” on page 115

041 TRAY MISSING / INSTALL TRAY 1 “MAP 041: Install Tray 1” on page 116



049 COVER OPEN / CLOSE FACEUP BIN WHEN DUPLEXING “MAP 049: Close Face-up Output Bin When Duplexing” onpage 122

074 COVER OPEN / CLOSE FRONT COVER “MAP 074: Close Front Cover” on page 125

075 COVER OPEN / CLOSE REAR COVER “MAP 075: Close Rear Cover” on page 129

200 DUPLEX ERROR / WRONG PAPER SIZE “MAP 200: Wrong Paper Size - Duplex” on page 131

201 TRAY <tray> ERROR / WRONG PAPER SIZE “MAP 201: Wrong Paper Size - Tray” on page 132


Table 4. Error Message with Error Code (continued)

Error Code Go To...

220 PAPER JAM / OPEN FRONT COVER “MAP 220: Paper Jam - Early Feed” on page 134

221 PAPER JAM / CHECK PAPER TRAY AND OPEN FRONTCOVER

“MAP 221: Paper Jam - Late Feed” on page 148

230 PAPER JAM / OPEN FRONT COVER AND REAR COVERS “MAP 230: Paper Jam - Late Exit” on page 162

232 PAPER JAM / OPEN REAR COVER “MAP 232: Paper Jam - Exit On” on page 167

250 PAPER JAM / CHECK DUPLEX AREA “MAP 250: Paper Jam - Duplex Early Registration” on page 171

253 PAPER JAM / CHECK DUPLEX AREA “MAP 253: Paper Jam - Late Duplex” on page 173

254 PAPER JAM / CHECK DUPLEX AREA “MAP 254: Paper Jam - Duplex On” on page 175

255 PAPER JAM / CHECK DUPLEX AREA “MAP 255: Paper Jam - Duplex Late Registration” on page 177

261 PAPER JAM / OPEN OFFSET BIN REAR COVER “MAP 261: Paper Jam - Late Offset” on page 179

262 PAPER JAM / OPEN OFFSET BIN REAR COVER “MAP 262: Paper Jam - Offset On” on page 182

272 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 272: Paper Jam - Exit On (Specific)” on page 184

275 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 275: Paper Jam - Early Exit Off” on page 190

276 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 276: Paper Jam - Exit On (Universal)” on page 192

430 MOTOR ERROR / POWER OFF/ON “MAP 430: Motor Error” on page 197

451 FAN ERROR / POWER OFF/ON “MAP 451: Fan Error” on page 202

454 FUSER ERROR / POWER OFF/ON “MAP 454: Fuser Error” on page 204

460 OFFSET ERROR / POWER OFF/ON “MAP 460: Offset Error” on page 206

511 LASER ERROR / POWER OFF/ON “MAP 511: Laser Error” on page 207

623 DATA ERROR / PRESS ENTER TO CONTINUE “MAP 623: Data Error” on page 209

630 NVM ERROR / POWER OFF/ON “MAP 630: NVM Error” on page 210

631 NVRAM ERROR / PARAMETERS RESET / PRESS ENTER “MAP 631: NVRAM Error” on page 211


Table 4. Error Message with Error Code (continued)

Error Code Go To...

650 SERVICE PORT / CALL SERVICE “MAP 650: Service Error” on page 212

651 HW ERROR / CALL SERVICE “MAP 651: Boot Error” on page 213

652 HW ERROR / CALL SERVICE “MAP 652: Memory Error” on page 214

653 HW ERROR / POWER OFF/ON “MAP 653: File Error” on page 216

654 HW ERROR / POWER OFF/ON “MAP 654: HW Error (MCU)” on page 217

661 CODE ERROR / PRESS ENTER nnn “MAP 661: Firmware Error” on page 219

671 DISK ERROR / CALL FOR SERVICE “MAP 671: Disk Error” on page 220

699 HW ERROR / POWER OFF/ON “MAP 699: HW Error (Offset)” on page 221

714 DUPLEX ERROR / RESEAT DUPLEX “MAP 714: Duplex Error” on page 222

772 ENV ERROR / RESEAT ENV TRAY “MAP 772: ENV Error” on page 223

795 OFFSET ERROR / RESEAT OFFSET BIN “MAP 795: Offset Error” on page 225

821 PS OPTION / RESEAT PS CF “MAP 821: PS Option” on page 226

831 ERROR nnnnn / CALL SERVICE “MAP 831: Controller Loop Trap” on page 227

851 IPDS OPTION / RESEAT IPDS CF “MAP 851: IPDS Option” on page 228

852 IPDS ADD MEM / POWER OFF/ON “MAP 852: IPDS Add Mem” on page 229

853 IPDS LOW MEM / POWER OFF/ON “MAP 853: IPDS Low Mem” on page 231

854 IPDS ERROR / RESET IPDS FONTS “MAP 854: IPDS Error” on page 232

860 NO HOST SYNC / PRESS ENTER “MAP 860: No CX Host Sync” on page 233

861 NO HOST SYNC / PRESS ENTER “MAP 861: No TX Host Sync” on page 234

862 SEND STATE / PRESS ENTER TO SEND PA1 “MAP 862: CX Key Request” on page 235

872 NETWORK OPT / RESEAT OPTION “MAP 872: Network Option” on page 236


Print Quality ProblemsLink to -- Table 5 on page 59

Before analyzing print quality (PQ) problems, verify that supply items (toner cartridge, bias transfer roll, and fuser)don’t need replacing. Also, check the items listed below.

The quality of the printed image depends upon many factors, some of which are controlled by the customer. Thefollowing customer-controlled items should be as described in the Infoprint 21 User’s Guide:v Toner Cartridgev Paper, envelopes, or transparenciesv Fuserv Bias transfer rollv Stable operating environment

– Temperature– Humidity

v Location– On a level surface– Proper ventilation– Shielded from direct sunlight– Low dust content in air– Not near wall outlets, steamers, electric heaters, volatile gasses, or open flame

v Supplies storage– At the warehouse– In the printer operating environment


Find the symptom, and then go to the suggested procedure.Table 5. Print Quality Problems

Symptom Go To...

Background “MAP 900: Background or Dark Image” on page 237

Black image “MAP 905: All Black Print” on page 240

Blank image “MAP 910: All Blank Print” on page 242

Damaged page “MAP 920: Damaged Page” on page 245

Dark image “MAP 900: Background or Dark Image” on page 237

Fusing “MAP 930: Not Fused or Partially Fused Image” on page 248

Light (under-toned) image “MAP 935: Light Image” on page 250

Registration of image “MAP 940: Image Registration” on page 253

Repeating (cyclical) spots or voids “MAP 941: Repeating Spots or Voids” on page 256

Residual image or ghosting “MAP 945: Residual or Ghost Images” on page 258

Skewed image “MAP 950: Skewed Image” on page 260

Spots “MAP 955: Spots on Prints” on page 263

Streaks, horizontal “MAP 965: Horizontal Streaks” on page 265

Streaks, vertical “MAP 970: Vertical Streaks” on page 268

Voids “MAP 975: Voids on Prints” on page 270

Voids, horizontal band “MAP 980: Horizontal Voids” on page 273

Voids, vertical band “MAP 985: Vertical Band Voids” on page 276


Coax/Twinax NIC Printing Problem (Printer)Symptom Explanation Suspected FRUs/Causes Probability

The printer is having problems printing with the Coax/TwinaxNIC.

Coax NIC 40%

Twinax NIC 40%

IBM AFP/IPDS Module 10%

Compact Flash 5%

Controller PCB 5%

Table 6. Coax/Twinax NIC Printing Problem (Printer)

Step Questions/Actions Yes No

1. Is the problem only with IPDS jobs? Go to step 2. Go to step 3.

2. Check the IPDS Status:a. Print a Service Page from Tray 1 to the Main Output

Bin (see “Printing the Service Page” on page 295.)

Is IPDS indicated on the Service Page?

Verify that there is enoughmemory for IPDS jobs (see theIBM Infoprint 21: User’s Guide).Go to step 3.

Reseat the IBM AFP/IPDSModule. If that does not fix theproblem, replace the IBMAFP/IPDS Module.

3. Power off and then power on the printer. Wait for theREADY message.

Does READY appear within 5 minutes?

Go to step 4. Return to “Solving the Problem”on page 46 with the new error

code or symptom.

4. Check printer function:a. Print a Service Page from Tray 1 to the Main Output


Can you print a Service Page?

Go to step 5 on page 61. Return to “Solving the Problem”on page 46 with the new error

code or symptom.


Table 6. Coax/Twinax NIC Printing Problem (Printer) (continued)


5. Is the twinax or coax NIC indicated on the ServicePage?

Go to step 6. Go to step 9.

6. Check the NIC:a. Print a NIC Service Page from Tray 1 to the Main

Output Bin (see “Printing the Service Page” onpage 295).

Can you print a NIC Service Page?


7. Check the job status:

When a job is sent, does the printer operator panelindicate the job’s arrival with any message?

The cabling and NIC are OK.Suspect a problem with menusettings, the IBM AFP/IPDSModule, the Controller Flash, orthe Controller PCB.

Go to step 8.

8. The NIC can communicate with the controller, but thesystem cannot communicate with the NIC.a. Check the cable connection at the back of the

twinax or coax NIC.

Is the connection light ON and the cableconnected?

Suspect a problem with thenetwork. Refer the systemadministrator to Twinax andCoax Configuration Guide,S544-5712, or call your nextlevel of support (see “TechnicalSupport” on page 618).

If the connection light is off, theproblem most likely is with thecustomer network. Ask thecustomer to verify their networksetup. If problems continue,replace the NIC.

9. There is a problem with the NIC or controller.a. Power off the printer.b. Reseat the NIC.c. Power on the printer.

Is the problem fixed?

Verify that the original customerjob prints correctly.

Go to step 10 on page 62.


Table 6. Coax/Twinax NIC Printing Problem (Printer) (continued)


10. Replace the NIC:1. Power off the printer.2. Replace the NIC.3. Power on the printer.


Replacing the NIC solved theproblem. Verify that the originalcustomer job prints correctly.

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Compact Flashv Controller PCB


Ethernet / Token-Ring NIC Printing Problem (Printer)Symptom Explanation Suspected FRUs/Causes Probability

The printer is having problems printing with the Ethernet orToken-Ring NIC.

Ethernet NIC 40%

Token Ring NIC 40%


Compact Flash 5%

Controller PCB 5%

Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer)


1. Is the problem only with IPDS jobs? Go to step 2. Go to step 3.

2. Check the IPDS Status:a. Print a Service Page from Tray 1 to the Main Output

Bin (see “Printing the Service Page” on page 295).

Is IPDS indicated on the Service Page?

Verify that there is enoughmemory for IPDS jobs (see theIBM Infoprint 21: User’s Guide).Go to step 3.

Reseat the IBM AFP/IPDSModule. If that does not fix theproblem, replace the IBMAFP/IPDS Module.

3. Power off and then power on the printer. Wait for theREADY message.

Does READY appear within 5 minutes?

Go to step 4. Return to “Solving the Problem”on page 46 with the new error

code or symptom.

4. Check printer function:a. Print a Service Page from Tray 1 to the Main Output


Can you print a Service Page?

Go to step 5 on page 64. Return to “Solving the Problem”on page 46 with the new error

code or symptom.


Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer) (continued)


5. Is the Ethernet or Token-Ring NIC indicated on theService Page?


6. Check the NIC:a. Print a NIC Service Page from Tray 1 to the Main


Can you print a NIC Service Page?


7. Check the job status:

When a job is sent, does the printer operator panelindicate the job’s arrival with any message?

The cabling and NIC are OK.Suspect a problem with menusettings, the IBM AFP/IPDSModule, the Controller Flash, orthe Controller PCB.

Go to step 8.

8. The NIC can communicate with the controller, but thesystem cannot communicate with the NIC.a. Check the cable connection at the back of the

Ethernet or Token-Ring NIC.

Is the connection light ON and the cableconnected?

There is probably a networkcabling problem or aconfiguration problem. Refer thesystem administrator to Ethernetand Token Ring ConfigurationGuide, S544-5711, or call yournext level of support (see“Technical Support” onpage 618).

If the connection light is off, theproblem most likely is with thecustomer network. Ask thecustomer to verify their networksetup. If problems continue,replace the NIC.

9. There is a problem with the NIC or controller.a. Power off the printer.b. Reseat the NIC.c. Power on the printer.


Verify that the original customerjob prints correctly.



Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer) (continued)


10. Replace the NIC:1. Power off the printer.2. Replace the NIC.3. Power on the printer.


Replacing the NIC solved theproblem. Verify that the originalcustomer job prints correctly.

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Compact Flashv Controller PCB


Electrical Noise / Intermittent Operation (Printer)Symptom Explanation Suspected FRUs/Causes Probability

The printer is having intermittent problems, operation or errorcodes.

Toner Cartridge 40%

Main Power Switch 20%

HVPS 20%

LVPS 120V, LVPS 230V 10%

Fuser Asm 120 v, Fuser Asm 230 v 5%

MCU PCB 2%

Controller PCB 1%

5 V DC PCB 1%

Main Motor 1%

Table 8. Electrical Noise (Printer)


1. If there is any other electrical equipment, such as thefollowing, within 10 feet of the printer, isolate each, oneat a time.v Generatorsv Devices using motorsv Radio transmittersv X-ray machines

Do you still have an electrical noise problem?

Go to step 2 on page 67. Permanently relocate the printeror the interfering equipment.


Table 8. Electrical Noise (Printer) (continued)


2. Isolate the Features.a. Remove all of the following options:v Duplex Asmv Offset Asmv Extra Traysv Env Tray Asm


Go to step 3. Connect the options one at atime until the printer againbecomes inoperative. Replacethe last feature installed.

3. Perform a Safety Check.a. Perform “Power-Receptacle Safety-Check” on

page 34 and check all ground connections (see“Safety Ground” on page 33).


Go to step 4 on page 68. If the problem is with the supplyoutlet, have the customercorrect the problem. If there is afaulty ground connection withinthe printer, repair or replace thatpart.


Table 8. Electrical Noise (Printer) (continued)


4. Repair/replace the following, one at a time. After each replacement, determine if the problem is fixed.v Toner Cartridgev Main Power Switchv HVPSv LVPS 120V, LVPS 230Vv Fuser Asm 120 v, Fuser Asm 230 v

CAUTION:<2-43> High Temperature; switch off the printer and allow at least 30 minutes for parts in this area to coolbefore handling.

v MCU PCBv Controller PCBv 5 V DC PCBv Main Motor

If you have replaced all these parts and are still having the problem, go to “End of Diagnosing Problems and the ProblemRemains” on page 43.


Excess NoiseSymptom Explanation Suspected FRUs/Causes Probability

The printer is creating excessive noise. Main Motor 40%

Gear Drive Asm 40%

Duplex Asm 10%

MCU PCB 5%

Harness (J34 - J341) 5%

Table 9. Excess Noise (Printer)


1. Check the paper supply:a. Check each tray and verify that the paper guides

are adjusted correctly to match the paper size in thetray.

b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the

Aux Tray (see “Printing the Service Page” onpage 295.)

Is excess noise still audible?

Go to step 2 on page 70. The problem might be with thecustomer job. Verify the originaljob prints correctly.


Table 9. Excess Noise (Printer) (continued)


2. Check the Paper Path:a. Power off the printer.b. Check the paper path throughout the entire printer

for blockage.c. Replace any damaged component.d. Print a Service Page from Tray 1 to the Main Output


Is excess noise still audible?

Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.

3. Print a page with and without duplex:a. Enter the Service Mode (see “Accessing Service

Mode” on page 280).b. Print a Service Page from Tray 1 to the Main Output

Bin using the Duplex option (see ″Printing a ServicePage″ on page x.)

c. Print a Service Page from Tray 1 to the Main OutputBin without using the Duplex option.

d. If no duplex unit is installed on this machine, go tostep 3.

Is excess noise audible only when using duplex?

Go to step 7 on page 72. Go to step 4.

4. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Enter the Service Mode (see “Accessing Service

Mode” on page 280).d. Run Diagnostic 1100 (see “Diagnostic Menu” on

page 284).

Do all gears rotate correctly without excess noise?

Replace the MCU PCB. Go to step 5 on page 71.




5. Check the Main Motor:a. Power off the printer.b. Remove the Main Motor, leaving the Harness (J29 -

J291) attached to the MCU PCB.

DANGER

<1-10> Hazardous voltages are present. Donot touch the pins or the sockets of the powerreceptacle. Do not attempt to measurevoltages or make any other checks at thepower receptacle, the power cord, or thepower supply input before you perform thePower-Receptacle Safety-Check. Make thesechecks only if you are a qualified servicerepresentative or a qualified electrician.Inform the customer if the voltages or otherchecks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.

c. Enter the Service Mode (see “Accessing ServiceMode” on page 280).

d. Run Diagnostic 1100 (see “Diagnostic Menu” onpage 284).

Does the Main Motor rotate correctly without excessnoise?

Go to step 6 on page 72. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Motorv MCU PCB




6. Check the Gear Drive:a. Power off the printer.b. Check for damage by manually rotating the Main

Motor and watching the Gear Drive Asm.

Does the Gear Drive Asm function correctly withoutexcess noise?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCB

Repair/replace the Gear DriveAsm.

7. Check the Harness (J34 - J341):1. Power off the printer.2. Check the Harness (J34 - J341) from the MCU PCB

to make sure that it is properly connected and notdamaged.

Is the harness free of damage and properlyconnected?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB

Repair/replace the Harness (J34- J341).


Operator Panel, Controller and Power Problems (Printer)Symptom Explanation Suspected FRUs/Causes Probability

The Operator Panel LEDs, the display, or the push buttonsdo not function correctly. This might indicate a powerproblem.

Operator Panel 40%


MCU PCB 18%

Controller PCB 10%

Compact Flash 1%

Memory DIMM 1%

5 V DC PCB 1%

Main Power Switch 1%

Harness (J4 - Operator Panel) 1%

Harness (J28 - J281) 1%

Harness (J1 - J101) 1%

Harness (AC - J285) 1%

Harness (J282 - J9, J288 - J9) 1%


Table 10. Operator Panel, Controller and Power Problems (Printer)


1. Check Symptom:a. Power on the printer.b. Wait 6 minutes to be sure the symptom does not

change.

Does INFOPRINT 21 INITIALIZING display during the6 minutes?


2. Do any motors (including the fan motor) turn duringthe first five seconds after the printer is poweredon?

Go to step 3. Go to step 7 on page 75.

3. Check the Controller PCB:a. Power off the printer.b. Reseat the Controller PCB into the MCU PCB.c. Power on the printer.

Does INFOPRINT 21 INITIALIZING display?

A bad connection probablycaused the problem. If theproblem happens again, go tostep 7 on page 75.

Go to step 4.

4. Check the Harness (J4 - Operator Panel):a. Power off the printer.b. Check the Harness (J4 - Operator Panel) from the

Controller PCB to the Operator Panel to make surethat it is correctly connected and not damaged.

Is the harness free of damage and correctlyconnected?

Go to step 5 on page 75. Repair/replace the Harness (J4 -Operator Panel).


Table 10. Operator Panel, Controller and Power Problems (Printer) (continued)


5. Check the Harness (J282 - J9, J288 - J9):a. Power off the printer.b. Check the Harness (J282 - J9, J288 - J9) from the

LVPS and the 5 V DC PCB to the Controller PCB tomake sure that it is correctly connected and notdamaged.


Go to step 6. Repair/replace the Harness(J282 - J9, J288 - J9).

6. Check the Harness (J1 - J101):a. Power off the printer.b. Check the Harness (J1 - J101) from the LVPS to

the 5 V DC PCB to make sure that it is correctlyconnected and not damaged.


Repair/replace the following:v Operator Panelv 5 V DC PCBv LVPS 120V, LVPS 230Vv Controller PCBv Memory DIMMv Compact Flash

Repair/replace Harness (J1 -J101).

7. Check the Power Receptacle:a. Power off the printer and remove the printer power

cord from the power outlet.b. Perform “Power-Receptacle Safety-Check” on

page 34 and check for the correct AC receptaclevoltage.

Is the power receptacle voltage correct?

Go to step 8 on page 76. A bad power outlet caused theproblem.




8. Check the Power Cord:a. Power off the printer.b. Disconnect the Power Cord from the printer.c. Check the continuity of the Power Cord.

Does the Power Cord have continuity?

Go to step 9. Replace the Power Cord.

9. Check the Harness (J28 - J281):a. Power off the printer.b. Check the Harness (J28 - J281) from the MCU PCB

to the LVPS to make sure that it is correctlyconnected and not damaged.


Go to step 10. Repair/replace the Harness (J28- J281).

10. Check the Harness (AC - J285):a. Check the Harness (AC - J285) from the AC input

plug to the LVPS to make sure that it is correctlyconnected and not damaged.

b. Check for continuity from J285, pins 1 and 2, to thecorresponding AC input plug pins.

Is the harness free of damage, correctly connected,and have continuity?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Power Switchv LVPS 120V, LVPS 230V

Repair/replace the Harness (AC- J285).

11. Does the I/O INITIALIZING message display andthen always stay on?

Go to “Ethernet / Token-RingNIC Printing Problem (Printer)”on page 63.

Go to step 12.

12. Does the INFOPRINT 21 INITIALIZING or PLEASEWAIT INITIALIZING message display and thenalways stay on?

Go to step 14 on page 77. Go to step 13 on page 77.




13. Check the Harness (J282 - J9, J288 - J9):a. Power off the printer.b. Check the Harness (J282 - J9, J288 - J9) from the

LVPS and the 5 V DC PCB to the Controller PCB tomake sure that it is correctly connected and notdamaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Operator Panelv Controller PCBv 5 V DC PCBv LVPS 120V, LVPS 230V

Repair/replace the Harness(J282 - J9, J288 - J9).

14. Check the Features:1. Remove the installed features installed, one at a

time, in the order listed. After each removal, checkto see if the problem still exists.v Coax NICv Twinax NICv Ethernet NICv Token Ring NICv Hard Drivev IBM AFP/IPDS Modulev Font Flash

Did removing features fix the problem?

Repair/replace the feature lastremoved to fix the problem.

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Compact Flashv Controller PCB


Offset Not Recognized (Printer)Go to “MAP 795: Offset Error” on page 225.


Duplex Not Recognized (Printer)Go to “MAP 714: Duplex Error” on page 222.


Envelope Not Recognized (Printer)Go to “MAP 772: ENV Error” on page 223.


Tray 2 Not Recognized (Printer)Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic did not detect Tray 2. Option Paper Drawer 30%

Paper Size Sensor Asm 5%

MCU PCB 4%

Harness (J33 - J331) 1%

Table 11. Tray 2 Not Recognized (Printer)


1. Are there two Option Paper Drawers installed? Go to step 2. Go to step 3.

2. a. Switch the Option Paper Drawers so that Tray 2becomes Tray 3.

Do you still have a problem recognizing Tray 2?

Go to step 4 on page 82. Replace the Option PaperDrawer (Tray 3).

3. Replace the Option Paper Drawer (Tray 2):a. Power off the printer.b. Replace the Option Paper Drawer.c. Power on the printer.


Install the original Option PaperDrawer. Go to step 4 onpage 82.

Problem solved. Verify theoriginal customer job printscorrectly.


Table 11. Tray 2 Not Recognized (Printer) (continued)



to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB



Tray 3 Not Recognized (Printer)Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic did not detect Tray 3. Option Paper Drawer 30%


MCU PCB 4%

Harness (J33 - J331) 1%

Table 12. Tray 3 Not Recognized (Printer)


1. Check the Option Paper Drawer (Tray 3):a. Switch the Option Paper Drawers so that Tray 3

becomes Tray 2.b. Power on the printer.


Go to step 2. Replace the Option PaperDrawer (Tray 2).







MAP 002: Install New Toner CartridgeSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected low toner. Toner Cartridge 90%

Toner Sensor Asm 5%

MCU PCB 2%

Interface PCB 1%

Harness (J23 - J231) 1%

Harness (J42 - J421) 1%

Table 13. Map 002: Install New Toner Cartridge


1. Replace the Toner Cartridge:a. Power off the printer.b. Replace the Toner Cartridge.c. Power on the printer.

Do you still have error code 002?

Go to step 2. Problem solved.


to the Interface PCB to make sure that it is correctlyconnected and not damaged.

Is the harness free of damage and does it havecontinuity?

Go to step 3 on page 85. Repair/replace the Harness (J23- J231).


Table 13. Map 002: Install New Toner Cartridge (continued)


3. Check the Harness (J42 - J421):1. Power off the printer.2. Check the Harness (J42 - J421) from the Toner

Sensor Asm to the Interface PCB to make sure thatit is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Toner Sensor Asmv MCU PCBv Interface PCBv Harness (J42 - J421)

Repair/replace the Harness (J42- J421)


MAP 006: Reseat Toner CartridgeSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic could not detect the Toner Cartridge. Toner Cartridge 80%

Toner Cartridge Key Sensor 17%

MCU PCB 2%

Harness (J25 - J251) 1%

Table 14. Map 006: Reseat Toner Cartridge


1. Replace the Toner Cartridge:Note: The Infoprint 21 checks for IBM Toner Cartridgesusing the Toner Cartridge Key Sensor. If a non-IBMToner Cartridge is installed, error code 006 isgenerated.a. Replace the IBM Toner Cartridge.




to the Toner Cartridge Key Sensor to make surethat it is correctly connected and not damaged.To access Harness (J25 - J251), see “TonerCartridge Key Sensor” on page 490.


Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Toner Cartridge Key Sensorv MCU PCB



MAP 008: Install New FuserSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Fuser Life has been reached. Fuser Asm 120 v, Fuser Asm 230 v 95%

MCU PCB 5%


Table 15. Map 008: Install New Fuser


1. Replace the Fuser Asm 120 v, Fuser Asm 230 v:

CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.1. Power off the printer.2. Replace the Fuser Asm 120 v, Fuser Asm 230 v.3. Power on the printer.4. Reset the fuser count:

a. Press the Menu key until you see MACHINEINFO MENU.

b. Press the Item key until you see RESETFUSER CTR.

c. Press the Enter key.d. When you see the RESET COUNTER? /+YES, -NO

message, press the + key to reset the currentvalue to 0.


Replace the MCU PCB. Problem solved.


MAP 011: Tray x EmptySymptom Explanation Suspected FRUs/Causes Probability

One of the following:v The MCU PCB does not detect the empty tray.v The MCU PCB incorrectly detects an empty tray.

550-Sheet Tray Asm 40%

Option Paper Drawer 30%

Feed Asm 8%


Feed PCB 5%

MCU PCB 4%

No Paper Actuator 4%

Harness (J33 - J331) 1%

Table 16. Map 011: Tray x Empty


1. This map diagnoses two error conditions:a. The MCU PCB does not detect the empty tray (error

code 011 does not occur when a tray is empty).b. The MCU PCB incorrectly detects an empty tray

(error code 011 occurs when a tray has paper).

Is error code 011 occurring when the tray haspaper?


2. Does the error code 011 specify Tray 1? Go to step 13 on page 92. Go to step 3.

3. Does the error code 011 specify Tray 2? Go to step 4 on page 90. Go to step 10 on page 91.


Table 16. Map 011: Tray x Empty (continued)


4. The error message specifies Tray 2.

Is there an Option Paper Drawer installed?



6. Check the Option Paper Drawer (Tray 2):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 2

becomes Tray 3.c. Power on the printer.

Does error code 011 specify Tray 2?


7. Check Tray 2:a. Power off the printer.b. Switch the trays so that Tray 2 becomes Tray 3.c. Power on the printer.


Replace the 550-Sheet TrayAsm (Tray 3).

Replace the Option PaperDrawer (Tray 2). If the problempersists, go to step 9 onpage 91.

8. Check Tray 2:a. Power off the printer.b. Switch the trays between Tray 1 and Tray 2.c. Power on the printer.


Go to step 9 on page 91. Replace the 550-Sheet TrayAsm in Tray 1.





to the Paper Sizing PCB to make sure that it iscorrectly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawerv Paper Size Sensor Asmv MCU PCB



11. Note: Based on answers to previous questions, Tray 3was specified in the error code 011.

Check the Option Paper Drawer (Tray 3):a. Power off the printer.b. Switch the Option Paper Drawers, including the

550-Sheet Tray Asms, so that Tray 3 becomes Tray2.

c. Power on the printer.



12. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asms so that Tray 2



Replace the 550-Sheet TrayAsm (currently in Tray 3).

Replace the Option PaperDrawer (currently Tray 2).




13. Check the No Paper Actuator:a. Power off the printer.b. Check the No Paper Actuator and ensure that it is

undamaged and working correctly.

Is the No-Paper Actuator intact and workingcorrectly?

Go to step 14. Repair/replace the No PaperActuator.

14. Check the No-Paper Photo Sensor on the Tray 1 FeedPCB:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 1.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Lift the No-Paper Actuator to actuate the No-Paper

Photo Sensor in the Feed PCB.

Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?









16. Is there an Option Paper Drawer installed? Go to step 17. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed PCBv 550-Sheet Tray Asm (Tray 1)v Paper Size Sensor Asmv MCU PCBv Feed Asm

17. Check the 550-Sheet Tray Asm (Tray 1):a. Power off the printer.b. Switch the 550-Sheet Tray Asms to that Tray 1



Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed PCBv Paper Size Sensor Asmv MCU PCBv Feed Asm

Replace the 550-Sheet TrayAsm (in Tray 2).

18. Does the error occur with Tray 1? Go to step 27 on page 95. Go to step 19.

19. Does the error occur with Tray 2? Go to step 20. Go to step 24 on page 94.

20. The error occurs with Tray 2.

Is there an Option Paper Drawer installed?





21. Check the Option Paper Drawer (Tray 2):a. Enter Service Mode (see “Accessing Service Mode”


page 284).d. Actuate the No-Paper Photo Sensor in Tray 2.



22. Are there two Option Paper Drawers installed? Go to step 23. Go to step 9 on page 91.


becomes Tray 3.c. Enter Service Mode (see “Accessing Service Mode”

on page 280.)d. Remove the 550-Sheet Tray Asm from Tray 2.e. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).f. Actuate the No-Paper Photo Sensor in Tray 2.


Replace the Option PaperDrawer (currently Tray 3). If theproblem persists, go to step 9on page 91.


24. Are there two Option Paper Drawers installed? Go to step 25 on page 95. Go to step 9 on page 91.




25. Check the Option Paper Drawer (Tray 3):a. Enter Service Mode (see “Accessing Service Mode”


page 284).d. Actuate the No-Paper Photo Sensor in Tray 3.




becomes Tray 2.c. Enter Service Mode (see “Accessing Service Mode”

on page 280.)d. Remove the 550-Sheet Tray Asm from Tray 3.e. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).f. Actuate the No-Paper Photo Sensor in Tray 3.


Replace the Option PaperDrawer (currently Tray 2). If theproblem persists, go to step 9on page 91.


27. Check the No-Paper Actuator:a. Power off the printer.b. Check the No Paper Actuator and ensure that it is

undamaged and working correctly.

Is the No-Paper Actuator intact and workingcorrectly?

Go to step 28 on page 96. Repair/replace the No PaperActuator.




28. Check the No-Paper Sensor on the Tray 1 Feed PCB:a. Enter Service Mode (see “Accessing Service Mode”


page 284).d. Lift the No-Paper Actuator to actuate the No-Paper

Photo Sensor on the Feed PCB.






Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v 550-Sheet Tray Asm (Tray 1)v Feed PCBv Paper Size Sensor Asmv MCU PCBv Feed Asm



MAP 012: (Aux/Env) EmptySymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Aux or Envelope Tray has no paper. Aux Tray Asm 45%

Env Tray Asm 45%

MCU PCB 5%

Interface PCB 2%

Harness (J23 - J231) 1%

Harness (J45 - J451) 1%

Env Connector - Female 1%

Table 17. Map 012: (Aux/Env) Empty


1. There are two reasons to be at this map.a. The MCU PCB does not detect the empty tray.b. The MCU PCB incorrectly detects an empty tray.

Is the MCU PCB always detecting a Tray Emptycondition?

Yes, the Tray Empty erroralways appears. Go to step 2.

No, the Tray Empty error neverappears. This will cause a 221Paper Jam when there is nopaper in the tray. Go to step 2.

2. Is the Tray Empty problem with the Aux Tray? Yes, the error is with the AuxTray. Go to step 3 on page 98.

No, the error is with theEnvelope Tray. Go to step 7 onpage 99.


Table 17. Map 012: (Aux/Env) Empty (continued)


3. Check the Aux Tray No-Paper Sensor Actuator:a. Power off the printer.b. Check the Aux Tray No-Paper Sensor Actuator and

ensure that it is not damaged and working correctly.c. Clean the Aux Tray No-Paper Sensor.

Is the Aux Tray No-Paper Sensor Actuator intactand working correctly?

Go to step 4. Repair/replace the Aux TrayNo-Paper Sensor Actuator.

4. Check the Aux Tray No-Paper Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the paper from the Aux Tray.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Aux Tray No-Paper Photo Sensor.

Did the Diagnostic display “Sensor/Switch OK”when the Aux Tray No-Paper Sensor was actuated?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCB

Go to step 5.








6. Check the Harness (J45 - J4511):a. Power off the printer.b. Check the Harness (J45 - J451) from the Interface

PCB to the Aux Tray No-Paper Photo Sensor tomake sure that it is correctly connected and notdamaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCB


7. Is there an Envelope Tray attached to this printer? Go to step 8. Replace the MCU PCB.

8. Check the Env No-Paper Actuator:a. Check the Env No-Paper Actuator and ensure that it

is not damaged and working correctly.b. Clean the Env No-Paper Sensor.

Is the Env No-Paper Actuator intact and workingcorrectly?

Go to step 9. Repair/replace the EnvNo-Paper Actuator.

9. Check the Env No-Paper Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the paper from the Env Tray.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Env No-Paper Photo Sensor.

Did the Diagnostic display “Sensor/Switch OK”when the Env No-Paper Sensor was actuated?









11. Check the Env Connector -Female:1. Power off the printer.2. Check the Env Connector -Female to make sure

that it is correctly connected and not damaged fromthe Interface PCB.

Is the connector in good condition?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCB

Repair/replace the EnvConnector - Female.


MAP 015: Tray x LowSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a tray is low on paper. Printing is stillpossible.


Paper Low Photo Sensor 20%


Feed Asm 10%


MCU PCB 3%

Harness (J33 - J331) 1%

Harness (J66 - J661, J662) 1%

Table 18. Map 015: Tray x Low


1. Verify the error:a. Power off the printer.b. Reload the specified tray with the correct size

paper.c. Make sure the paper size guides are against the

paper.d. Close the tray.e. Power on the printer.



2. Does error code 015 specify tray 1? Go to step 18 on page 106. Go to step 3 on page 102.


Table 18. Map 015: Tray x Low (continued)


3. Does error code 015 specify tray 2? Go to step 4. Go to step 12 on page 104.

4. Is there an Option Paper Drawer installed? Go to step 5. Replace the MCU PCB.





Switch the Tray 2 and Tray 3drawers back.


Go to step 7.

7. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Switch the 550-Sheet Tray Asms between Tray 3

and Tray 2.c. Power on the printer.







Go to step 9 on page 103. Replace the 550-Sheet TrayAsm (in Tray 1).




9. Check the Option Paper Drawer Paper Low PhotoSensor Actuator (Tray 2):a. Power off the printer.b. Check the Option Paper Drawer Low Paper Sensor

Actuator and ensure that it is not damaged andworking correctly.

c. Clean the Option Paper Drawer Low Paper Sensor.

Is the Option Paper Drawer Low Paper SensorActuator intact and working correctly?

Go to step 10. Repair/replace the Option PaperDrawer Low Paper SensorActuator.

10. Check the Option Paper Drawer Paper Low PhotoSensor (Tray 2):a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the 550-Sheet Tray Asm from the Option

Paper Drawer (Tray 2).c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Paper Low Photo Sensor in the Option

Paper Drawer (Tray 2).

Did the Diagnostic display “Sensor/Switch OK”when the Low Paper Sensor was actuated?






to make sure that it is correctly connected and notdamaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v Paper Size Sensor Asmv MCU PCB


12. Is there two Option Paper Drawers installed? Go to step 13. Replace the MCU PCB.













15. Check the Option Paper Drawer Paper Low PhotoSensor Actuator (Tray 3):a. Power off the printer.b. Check the Option Paper Drawer Low Paper Sensor

Actuator and ensure that it is not damaged andworking correctly.

c. Clean the Option Paper Drawer Low Paper Sensor.

Is the Option Paper Drawer Low Paper SensorActuator intact and working correctly?

Go to step 16. Repair/replace the Option PaperDrawer Low Paper SensorActuator.

16. Check the Option Paper Drawer Paper Low PhotoSensor (Tray 3):a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the 550-Sheet Tray Asm from the Option

Paper Drawer (Tray 3).c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Paper Low Photo Sensor in the Option

Paper Drawer (Tray 3).











18. Check the Feed Asm Paper Low Photo SensorActuator:a. Power off the printer.b. Check the Feed Asm Low Paper Sensor Actuator

and ensure that it is not damaged and workingcorrectly.

c. Clean the Feed Asm Low Paper Sensor.

Is the Feed Asm Low Paper Sensor Actuator intactand working correctly?

Go to step 19. Repair/replace the Feed AsmLow Paper Sensor Actuator.

19. Check the Feed Asm Paper Low Photo Sensor (Tray 1):a. Enter Service Mode (see “Accessing Service Mode”


page 284).d. Actuate the Paper Low Photo Sensor in the Feed

Asm (Tray 1) by lifting the Feed Asm Low PaperSensor Actuator.










21. Is there an Option Paper Drawer installed? Go to step 23. Go to step 22.

22. Check the Harness (J66 - J661, J662):a. Power off the printer.b. Check the Harness (J66 - J661, J662) from the Low

Paper Photo Sensor to the Feed PCB to make surethat it is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Low Photo Sensorv 550-Sheet Tray Asm (Tray 1)v Paper Size Sensor Asmv MCU PCBv Feed Asm

Repair/replace the Harness (J66- J661, J662).




Go to step 24 on page 108. Replace the 550-Sheet TrayAsm (in Tray 2).




24. Check the Harness (J66 - J661, J662):1. Power off the printer.2. Check the Harness (J66 - J661, J662) from the Low

Paper Photo Sensor to the Feed PCB to make surethat it is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Low Photo Sensorv Paper Size Sensor Asmv MCU PCBv Feed Asm



MAP 016: Adjust Guides For Paper Size Or Set Size In MenuSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the menu is set for autosense, but thepaper guides are not in an autosense position.



MCU PCB 2%

Harness (J33 - J331) 1%

Table 19. Map 016: Adjust Guides For Paper Size Or Set Size In Menu


1. This error is usually caused by the 550-Sheet Tray Asminserted skewed.

Is the 550-Sheet Tray Asm inserted correctly?

Go to step 2. Reinsert the tray or replace the550-Sheet Tray Asm

2. This error can also be caused by incorrect settings inthe printer menu.

Is the TRAnSIZ item in the Paper Menu set toAUTO?

Go to step 3 on page 110. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv MCU PCB


Table 19. Map 016: Adjust Guides For Paper Size Or Set Size In Menu (continued)


3. Check the 550-Sheet Tray Asm Guides:a. Remove the tray with the error.b. Verify correct operation of the paper guides.c. Set the paper guides to an autosensed position.

Note: Select AUTO for the following paper sizes:LETTER, LEGAL, FOLIO, A4, B5-JIS, A5, or EXEC.For other paper sizes, select that size in the PaperMenu.

Is the 550-Sheet Tray Asm working correctly?

Go to step 4. Repair/replace 550-Sheet TrayAsm.




Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCBv Controller PCB



MAP 017: Adjust Guides For Paper Size Or Set Size In MenuSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected an error with the paper sizeauto-sensing circuit.



MCU PCB 2%

Harness (J33 - J331) 1%

Table 20. Map 017: Adjust Guides For Paper Size Or Set Size In Menu


1. Theoretically, this error should never occur. Continuewith the following map steps, but also consider callingyour next level of support.

Is the TRAnSIZ item in the Paper Menu set toAUTO?

Go to step 2. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv MCU PCB




Go to step 3 on page 112. Repair/replace 550-Sheet TrayAsm.


Table 20. Map 017: Adjust Guides For Paper Size Or Set Size In Menu (continued)








MAP 031: Unload Paper From Main Output BinSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Main Output Bin is full of paper. Full Stack Photo Sensor 60%

MCU PCB 35%

Harness (J31 - J311) 5%

MCU Logic did not detect that the Main Output Bin is full ofpaper.

Full Stack Photo Sensor 60%

MCU PCB 35%

Harness (J31 - J311) 5%

Table 21. Map 031: Unload Paper From Main Output Bin


1. There are two reasons to be at this map.a. The MCU PCB did not detect Full Stack.b. The MCU PCB always detects Full Stack.

Note: If the Offset Output Bin is not installed, theprinter can print 107 pages to the main output bin afterthe Full Stack Photo Sensor stops toggling. If the OffsetOutput Bin is installed, the printer can print 7 pagesafter the Full Stack Photo Sensor stops toggling.

Is the MCU PCB always detecting a Full Stackcondition?

Yes, the Full Stack error alwaysappears. Go to step 2 onpage 114.

No, the Full Stack error neverappears. This will cause a 272Paper Jam. Go to step 2 onpage 114.


Table 21. Map 031: Unload Paper From Main Output Bin (continued)


2. Check the Full Stack Photo Sensor Actuator:a. Power off the printer.b. Check the Full Stack Sensor Actuator and ensure

that it is not damaged and working correctly.c. Clean the Full Stack Sensor.

Is the Full Stack Sensor Actuator intact and workingcorrectly?

Go to step 3. Repair/replace the Full StackActuator.

3. Check the Full Stack Photo Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the paper from the Main Output Bin.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Full Stack Photo Sensor by lifting the

Full Stack Actuator.

Did the Diagnostic display “Sensor/Switch OK”when the Full Stack Photo Sensor was actuated?

Replace the MCU PCB. Go to step 4.


to the Full Stack Photo Sensor to make sure that itis correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Full Stack Photo Sensorv MCU PCB



MAP 035: Unload Paper From Offset BinSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Offset Bin is full of paper. Offset Asm 60%

MCU PCB 35%

Harness (J35 - J351) 5%

MCU Logic did not detect that the Offset Bin is full of paper. Offset Asm 60%

MCU PCB 35%

Harness (J35 - J351) 5%

Table 22. Map 035: Unload Paper From Offset Bin


1. There are two reasons to be at this map.a. The MCU PCB did not detect Full Stack.b. The MCU PCB always detects Full Stack.

Is the MCU PCB always detecting a Full Stackcondition?

Yes, the Full Stack error alwaysappears. Go to step 2.

No, the Full Stack error neverappears. This will cause a 272Paper Jam. Go to step 2.




Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB



MAP 041: Install Tray 1Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected that Tray 1 is missing. 550-Sheet Tray Asm 60%


MCU PCB 5%

Feed Asm 3%

Harness (J33 - J331) 1%

Harness (J66 - J661, J662) 1%

Table 23. Map 041: Install Tray 1


1. Check the 550-Sheet Tray Asm:a. Power off the printer.b. Remove the 550-Sheet Tray Asm.c. Check the paper-lift mechanism for damage or wear.

Make sure to check the copper tray connectorcontacts located on the left side of the tray asm,and their matching contacts inside the tray opening.

d. Install the 550-Sheet Tray Asm.e. Power on the printer.



2. Is there an Option Paper Drawer installed on thisprinter?



Table 23. Map 041: Install Tray 1 (continued)


3. Check the 550-Sheet Tray Asm (Tray 1):a. Switch the 550-Sheet Tray Asm between Tray 1 and

Tray 2.

Do you still have a “041 Tray Missing - Tray 1”error?

Go to step 4. Replace the 550-Sheet TrayAsm Asm (Tray 2).





5. Check the Harness (J66 - J661, J662):1. Power off the printer.2. Check the Harness (J66 - J661, J662) from the Lift

Control Photo Sensor to the Feed PCB to makesure that it is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Lift Control Photo Sensorv Feed PCBv Paper Size Sensor Asmv MCU PCBv 550-Sheet Tray Asm







MCU PCB 4%

Harness (J33 - J331) 1%



1. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Remove the Tray 2 550-Sheet Tray Asm.c. Check the tray for damage and wear.d. Install the 550-Sheet Tray Asm.e. Power on the printer.



2. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asm between Tray 2 and

Tray 1.c. Power on the printer.


Go to step 3 on page 119. Replace the 550-Sheet TrayAsm Asm (Tray 1).

















Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v Paper Size Sensor Asmv MCU PCB







MCU PCB 4%

Harness (J33 - J331) 1%



1. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Remove the 550-Sheet Tray Asm.c. Check for damage or wear.d. Install the 550-Sheet Tray Asm.e. Power on the printer.


Go to step 2 on page 121. Problem solved.




2. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Switch the Tray 2 and Tray 3 550-Sheet Tray Asm

so that the Tray 2 550-Sheet Tray Asm becomes theTray 3 550-Sheet Tray Asm.



Go to step 3. Replace the 550-Sheet TrayAsm Asm currently in Tray 2.











MAP 049: Close Face-up Output Bin When DuplexingSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Face-up Output Bin is open whentrying to print duplex.

Duplex Face-up Photo Sensor 80%

MCU PCB 15%

Harness (J34 - J341) (see “Harness (J34-P341)” onpage 403)

4%

Rear Cover Asm (With Face-Up Bin), Rear CoverAsm (Without Face-Up Bin)

1%

Table 26. Map 049: Close Face-up Output Bin When Duplexing


1. Is there a duplex unit installed on this printer? Go to step 2. Replace the MCU PCB.

2. Is the customer trying to print a duplex job with theFace-up Output Bin open?

The printer cannot print duplexwith the Face-up Output Binopen. Close the Face-up OutputBin to print duplex.

Go to step 3.

3. Is the customer trying to print with the Face-upOutput Bin open?

The print job might be duplex,which would generate this error.Check the customer’s driversand printer settings.



Table 26. Map 049: Close Face-up Output Bin When Duplexing (continued)


4. Check the Duplex Face Up Photo Sensor Actuator:a. Power off the printer.b. Check the Duplex Face Up Photo Sensor Actuator

and ensure that it is not damaged and workingcorrectly.

c. Clean the Duplex Face Up Photo Sensor.

Is the Duplex Face Up Photo Sensor Actuator intactand working correctly?

Go to step 5. Repair/replace the DuplexFace-up Photo Sensor Actuator.

5. Check the Duplex Face Up Photo Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Open the Rear Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Actuate the Face Up Photo Sensor by blocking the

sensor with a piece of paper.

Does the Diagnostic display “Sensor/Switch OK”when the Face Up Photo Sensor is blocked?


6. Check the Rear Cover:a. Check the Rear Cover to ensure that the Face Up

Tab on the Rear Cover that activates the Face UpPhoto Sensor is intact and working correctly.

Is the Rear Cover in good condition?

Replace the MCU PCB. Replace the Rear Cover.


Table 26. Map 049: Close Face-up Output Bin When Duplexing (continued)








MAP 074: Close Front CoverSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Front Cover is open. Front Cover Interlock Switch 80%

MCU PCB 10%


Harness (J28 - J281) 1%

Front Cover Asm 1%

Table 27. Map 074: Close Front Cover


1. Check the Front Cover Interlock Switch:a. Power on the printer.b. Open the Front Cover.c. Manually activate the Front Cover Interlock Switch.d. Ensure that the metal actuator on the switch is

intact, not deformed and working correctly.

Does error code 074 occur with the Front CoverInterlock Switch activated?

Go to step 2 on page 126. The Front Cover Asm is notactivating the Front CoverInterlock Switch. Replace theFront Cover Asm if the stand-offon the Front Cover Asm thatactuates the Front CoverInterlock Switch is broken.


Table 27. Map 074: Close Front Cover (continued)


2. Check the Front Cover Interlock Switch:a. Power off the printer.b. Disconnect P/J 284 from the LVPS.c. Check the continuity of the Front Cover Interlock

Switch on harness J284 from pin 1 to pin 2:v The switch should have continuity when

activated.v The switch should not have continuity when not

activated.

Does the Front Cover Interlock Switch havecontinuity?

Reconnect P/J284. Go to step 3on page 127.

Replace the Front CoverInterlock Switch.




3. Check the 24 V DC on the LVPS:

DANGER

<1-10> Hazardous voltages are present. Do nottouch the pins or the sockets of the powerreceptacle. Do not attempt to measure voltagesor make any other checks at the powerreceptacle, the power cord, or the power supplyinput before you perform the Power-ReceptacleSafety-Check. Make these checks only if you area qualified service representative or a qualifiedelectrician. Inform the customer if the voltages orother checks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.

a. Reconnect P/J284 on the LVPS.b. Power on the printer.c. Measure the following voltage:

PJ284-2 to frame ground: 24 V DC

Is there 24 V DC between PJ284-2 and frameground?

Go to step 4 on page 128. Replace the LVPS 120V, LVPS230V.







Repair/replace the following:v MCU PCBv LVPS 120V, LVPS 230V



MAP 075: Close Rear CoverSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Rear Cover is open. Rear Cover Interlock Switch 90%

MCU PCB 7%

Rear Cover Asm (With Face-Up Bin) Rear Cover Asm(Without Face-Up Bin)

3%

Table 28. Map 075: Close Rear Cover


1. Check the Rear Cover Interlock Switch:a. Power on the printer.b. Open the Rear Cover.c. Manually activate the Rear Cover Interlock Switch.d. Ensure that the metal actuator on the switch is

intact, not deformed and working correctly.

Does error code 075 occur when the Rear CoverInterlock Switch activated?

Go to step 2 on page 130. The Rear Cover is not activatingthe Rear Cover Interlock Switch.Replace the Rear Cover Asm(With Face-Up Bin), Rear CoverAsm (Without Face-Up Bin) ifthe stand-off on the Rear Coverthat actuates the Rear CoverInterlock Switch is broken.


Table 28. Map 075: Close Rear Cover (continued)


2. Check the Rear Cover Interlock Switch:1. Power off the printer.2. Disconnect P/J30 from the MCU PCB.3. Check the continuity of the Rear Cover Interlock

Switch on Harness J30 from pin 1 to pin 2:v The switch should have continuity when

activated.v The switch should not have continuity when not

activated (the cover is open).

Is the Rear Cover Interlock Switch operatingcorrectly?

Replace the MCU PCB. Replace the Rear CoverInterlock Switch.


MAP 200: Wrong Paper Size - DuplexSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected that the paper traveling through theduplex unit is the wrong size

MCU PCB 50%

Duplex Asm 50%

Table 29. Map 200: Wrong Paper Size - Duplex


1. Does the printer have a duplex unit installed? Go to step 2. Replace the MCU PCB.

2. Check the paper:1. Power off the printer.2. Remove all paper from the printer.3. Verify all paper is within the specification for duplex

printing. See the Infoprint 21 User’s Guide for paperspecifications.

Is the paper within the specification for duplexprinting?


Replace the paper with a correctsize of paper or stop printingduplex.


MAP 201: Wrong Paper Size - TraySymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the tray does not contain the paper sizespecified in the Paper Menu.



MCU PCB 2%

Harness (J33 - J331) 1%

Table 30. Map 201: Wrong Paper Size - Tray


1. This error is usually caused by incorrect settings in theprinter menu.

Is the paper size in the printer menu set for″autosense ″?

Go to step 2. Set the menu for the correctpaper size, or use autosense. Ifthe problem persists, go to step2.




Go to step 3 on page 133. Repair/replace 550-Sheet TrayAsm.


Table 30. Map 201: Wrong Paper Size - Tray (continued)








MAP 220: Paper Jam - Early FeedSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Registration Sensor was activatedtoo soon after the Feed Clutch was activated.

Registration Sensor 15%

Feed Roll Clutch 10%

Registration Actuator 8%



Paper Handling Asm 8%

Feed Asm 7%


Main Motor 5%

Gear Drive Asm 5%

Pick Clutch - Electric 5%

Feed PCB 3%

MCU PCB 3%

Paper Size PCB 3%

Interface PCB 3%

Harness (J43 - J432, J433) 1%

Harness (J33 - J331) 1%

Harness (J51 - J511) 1%

Harness (J23 - J231) 1%


Table 31. Map 220: Paper Jam - Early Feed


1. Check the paper:a. Remove the paper from all trays, and reload with

fresh, dry paper.b. Run Service Pages from all trays, including the Aux

tray. See “Printing the Service Page” on page 295.

Does error code 220 occur from all trays?

Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.

2. Does error code 220 occur with all inputs? Go to step 3. Go to step 11 on page 139.

3. Check the paper path:a. Power off the printer.b. Check the paper path from all trays to the

Registration Sensor for blockage. Especially checkbetween the Center Registration Chute and LowerRegistration Chute in the Paper handling Asm.

c. Replace any damaged component.d. Print a Service Page from Tray 1 to the Main Output


Does error code 220 occur?


4. Check the Registration Sensor Actuator:a. Power off the printer.b. Check the Registration Sensor Actuator and ensure

that it is not damaged and working correctly.c. Clean the Registration Sensor.

Is the Registration Sensor Actuator intact andworking correctly?

Go to step 5 on page 136. Repair/replace the RegistrationSensor Actuator.


Table 31. Map 220: Paper Jam - Early Feed (continued)


5. Check the Registration Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Open the Front Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Move the Registration Actuator to activate the

Registration Sensor.

Did the Diagnostic display “Sensor/Switch OK”when the Registration Sensor was actuated?






7. Check the Harness (J43 - J432, J433):a. Power off the printer.b. Check the Harness (J43 - J432, J433) from the

Interface PCB and the Registration Sensor to makesure that it is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCB





8. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Close the Front Cover.d. Enter Service Mode (see “Accessing Service Mode”

on page 280.)e. Run Diagnostic 1100 (see “Diagnostic Menu” on

page 284).

Do all gears rotate correctly?







DANGER


c. Enter Service Mode (see “Accessing Service Mode”on page 280.)


Does the Main Motor rotate correctly?







Does the Gear Drive Asm function correctly?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Handling Asm


11. Does error code 220 occur with the Aux Tray? Go to step 12. Go to step 15 on page 140.

12. Check the paper path:a. Check the paper path between the Aux Tray input

and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output




13. Check the Aux Pick Up Solenoid:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Run Diagnostic 1260 (see “Diagnostic Menu” on

page 284).

Did the Aux Pick Up Solenoid make a ‘click’ soundwhen this diagnostic was run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Trayv MCU PCB








Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm


15. Does error code 220 occur with the Env Tray? If noEnv Tray is installed on this machine answer no.


16. Check the paper path:a. Check the paper path between the Envelope

Feeder and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output




17. Replace the Env Tray Asm:a. Replace the Env Tray Asm.b. Print a Service Page from Tray 1 to the Main Output



Replace the Env Tray Asm. Goto step 18 on page 141.





18. Check the Env Connector -Female:a. Check the Env Connector -Female to make sure



Go to step 19. Repair/replace the EnvConnector - Female.




Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm


20. Does the printer have an Option Paper Drawerinstalled (Tray 2)?


21. The error only occurs with Tray 1. Check the paperpath:a. Check the paper path between the 550-Sheet Tray

Asm (Tray 1) and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output



Go to step 22 on page 142. Problem solved. Verify theoriginal customer job printscorrectly.




22. Check the Pick Clutch:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Pick Clutch make a ‘click’ sound whenthis diagnostic is run?





Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCB


24. Check the Feed Clutch:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Feed Clutch make a ‘click’ sound whenthis diagnostic is run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv 550-Sheet Tray Asmv Paper Handling Asmv MCU PCB

Go to step 23.

25. Does the printer have two Option Paper Drawersinstalled (Tray 2 and Tray 3)?


26. Does error code 220 occur with Tray 2? Go to step 27 on page 143. Go to step 21 on page 141.




27. Does error code 220 also occur with Tray 1? Go to step 28. Go to step 30.

28. Check the paper path:a. Check the paper path between the 550-Sheet Tray





29. Check the Feed Clutch for the Feed Asm:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Feed Asm Feed Clutch make a ‘click’sound when this diagnostic is run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCBv Paper Handling Asm


30. The error only occurs with Tray 2. Check the paperpath:a. Check the paper path between the 550-Sheet Tray








31. Check the 550-Sheet Tray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms between Tray 2

and Tray 1.b. Print a Service Page from Tray 2 to the Main Output



Go to step 32. Replace the 550-Sheet TrayAsm (in Tray 1).

32. Replace the Option Paper Drawer (Tray 2):a. Power off the printer.b. Replace the Option Paper Drawer.c. Print a Service Page from Tray 2 to the Main Output



Install the original Option PaperDrawer. Go to step 33.





Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Size Sensor Asm


34. Does error code 220 occur with Tray 3? Go to step 35. Go to step 38 on page 145.

35. Does error code 221 also occur with Tray 2 or Tray1?





36. The error only occurs with Tray 3. Check the 550-SheetTray Asm (Tray 3):a. Switch the 550-Sheet Tray Asms between Tray 3

and Tray 2.b. Print a Service Page from Tray 2 to the Main Output


Does error code 220 occur with Tray 2?


Go to step 37.


becomes Tray 2.b. Print a Service Page from Tray 2 to the Main Output



Replace the Option PaperDrawer (in Tray 2).



39. Does error code 220 also occur with Tray 1? Go to step 28 on page 143. Go to step 40.

40. The error occurs with Tray 2. Check the 550-Sheet TrayAsm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2















42. Check the Registration Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”

on page 280.)c. Run Diagnostic 1280 (see “Diagnostic Menu” on

page 284).

Does the Registration Clutch make a ‘click’ soundwhen this diagnostic is run?

Replace the MCU PCB. Go to step 43.








44. Check the Harness (J43 - J432, J433):1. Power off the printer.2. Check the Harness (J43 - J432, J433) from the

Interface PCB and the Registration Clutch to makesure that it is correctly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCB



MAP 221: Paper Jam - Late FeedSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Registration Sensor was activatedtoo late after the Feed Clutch was activated.

Registration Sensor 15%

Feed Roll Clutch 10%

Registration Actuator 7%


Aux Tray Asm 7%



Feed Asm 6%


Main Motor 4%

Gear Drive Asm 4%

Pick Clutch - Electric 4%

Feed PCB 3%

MCU PCB 3%

Paper Size PCB 3%

Interface PCB 2%

Aux Drive Gear 1%

Harness (J43 - J432, J433) 1%

Harness (J33 - J331) 1%

Harness (J51 - J511) 1%

Harness (J23 - J231) 1%


Table 32. Map 221: Paper Jam - Late Feed


1. Check the No Paper Sensor:a. Remove all paper from the printer.b. Print a Service Page from all trays including the Aux

Tray (see “Printing the Service Page” on page 295).After each page, power off the printer and re-enterService Mode.You should get error code 011 when you print fromTray 1, Tray 2, or Tray 3. You should get error code012 when you print from the Aux Tray or theEnvelope Feeder.

Does error code 221 occur when printing from anytray?

The No-Paper Photo Sensor isnot working correctly.v If error code 221 occurred

from Tray 1, Tray 2, or Tray3, go to “MAP 011: Tray xEmpty” on page 89.

v If error code 221 occurredfrom the Aux tray or theEnvelope Feeder, go to “MAP012: (Aux/Env) Empty” onpage 97.

Go to step 2.

2. Check the paper:a. Reload all paper trays including the Aux Tray with

fresh, dry paper.b. Print a Service Page from all trays, including the

Aux Tray. See “Printing the Service Page” onpage 295).If you get error code 221 from any tray, power offthe printer, clear any paper jams, and re-enterService Mode to print from the next tray.

Does error code 221 occur from all trays?



Table 32. Map 221: Paper Jam - Late Feed (continued)


3. Check the paper path:a. Check the paper path from all trays to the

Registration Sensor for blockage or damaged parts.Especially check between the Center RegistrationChute and Lower Registration Chute in the PaperHandling Asm.

b. Replace any damaged part.c. Print a Service Page from Tray 1 to the Main Output




4. Check the Registration Sensor Actuator:a. Check the Registration Sensor Actuator and ensure

that it is not damaged and working correctly.b. Clean the Registration Sensor.

Is the Registration Sensor Actuator intact andworking correctly?

Go to step 5. Repair/replace the RegistrationSensor Actuator.

5. Check the Registration Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Open the Front Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Move the Registration Actuator to activate the

Registration Sensor.

Did the Diagnostic display “Sensor/Switch OK”when the Registration Sensor was actuated?












Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCB


8. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Close the Front Cover.d. Enter Service Mode (see “Accessing Service Mode”

on page 280.)e. Run Diagnostic 1100 (see “Diagnostic Menu” on

page 284).

Do all gears rotate correctly?







DANGER


c. Enter Service Mode (see “Accessing Service Mode”on page 280.)


Does the Main Motor rotate correctly?








Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Handling Asm


11. Does error code 221 occur from the Aux Tray? Go to step 12. Go to step 15 on page 154.

12. Check the paper path:a. Power off the printer.b. Check the paper path between the Aux Tray input

and the Registration Sensor for foreign material ordamaged parts.

c. Replace any damaged part.d. Print a Service Page from the Aux Tray to the Main




13. Check the Aux Pick Up Solenoid:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”


page 284).

Did the Aux Pick Up Solenoid make a ‘click’ soundwhen this diagnostic was run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv Aux Drive Gearv Gear Drive Asmv MCU PCBv Interface PCB








Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm


15. Does error code 221 occur from the Env Tray? If noEnv Tray is installed on this machine, answer no.


16. Check the paper path:a. Power off the printer.b. Check the paper path between the Env Tray input

and the Registration Sensor for foreign material ordamaged parts.

c. Replace any damaged part.d. Print a Service Page from the envelope feeder to

the Main Output Bin (see “Printing the ServicePage” on page 295.)



17. Check the Env Connector -Female:a. Check the Env Connector -Female to make sure



Go to step 18 on page 155. Repair/replace the EnvConnector - Female.







Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm


19. Does the printer have a second paper tray (Tray 2)installed?


20. The error only occurs from Tray 1. Check the paperpath:a. Power off the printer.b. Check the paper path between the 550-Sheet Tray

Asm (Tray 1) and the Registration Sensor forforeign material or damaged parts.

c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output


Does error code 221 occur from Tray 1?





21. Check the Pick Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Pick Clutch make a ‘click’ sound whenthis diagnostic is run?





Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCB


23. Check the Feed Clutch:a. Enter Service Mode (see “Accessing Service Mode”


page 284).Note: Diagnostic 1250 actuates the feed clutchesfor all trays (Tray 1, Tray 2, and Tray 3). Check onlyfor the Tray 1 Feed Clutch.

Does the Tray 1 Feed Clutch make a ‘click’ soundwhen this diagnostic is run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv 550-Sheet Tray Asmv Gear Drive Asmv Paper Handling Asmv MCU PCB

Go to step 22.

24. Does the printer have two Option Paper Drawersinstalled (Tray 2 and Tray 3)?






26. Does error code 221 also occur with Tray 1? Go to step 27. Go to step 29 on page 158.

27. Check the paper path:a. Power off the printer.b. Check the paper path from the 550-Sheet Tray Asm

(Tray 2) to the Registration Sensor for foreignmaterial or damaged parts.





28. Check the Feed Clutch for the Feed Asm:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”


page 284).Note: Diagnostic 1250 actuates the feed clutchesfor all trays (Tray 1, Tray 2, and Tray 3). Check onlyfor the Tray 2 Feed Clutch.

Does the Tray 2 Feed Asm Feed Clutch make a‘click’ sound when this diagnostic is run?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCBv Paper Handling Asm





29. The error only occurs from Tray 2. Check the paperpath:a. Check the paper path from the 550-Sheet Tray Asm

(Tray 2) to the Registration Sensor for foreignmaterial or damaged parts.





30. Check the 550-Sheet Tray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2




Go to step 31. Replace the 550-Sheet TrayAsm (in Tray 1).




Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v MCU PCBv Paper Size Sensor Asm


32. Does error code 221 occur from Tray 3? Go to step 33. Go to step 36 on page 159.

33. Does error code 221 also occur from Tray 2 or Tray1?





34. The error only occurs from Tray 3. Check the 550-SheetTray Asm (Tray 3):a. Switch the 550-Sheet Tray Asms so that Tray 3





Go to step 35.







36. Does error code 221 occur from Tray 2? Go to step 37. Go to step 20 on page 155.

37. Does error code 221 also occur from Tray 1? Go to step 27 on page 157. Go to step 38.

38. The error occurs from Tray 2. Check the 550-SheetTray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2


















Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Size Sensor Asm




page 284).




MAP 230: Paper Jam - Late ExitSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected that the Registration Sensor wasactivated at power on.


Registration Clutch - Electric 30%

Toner Cartridge 15%


BTR Support Asm 6%

Gear Drive Asm 4%

MCU PCB 2%

Interface PCB 1%

Harness (J27, J11, J262-J271) 1%

Harness (J23 - J231) 1%

Harness (J43 - J432, J433) 1%

Table 33. Map 230: Paper Jam - Late Exit



fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output



Go to step 2 on page 163. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.


Table 33. Map 230: Paper Jam - Late Exit (continued)


2. Check the paper path:a. Check the paper path from the Registration Sensor

to the Fuser Asm for fragments of paper or otherforeign material that could block the paper path.







page 284).



4. Check the Registration Sensor:a. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).b. Activate the registration sensor.

Does the Registration Sensor work correctly?

Go to step 5 on page 164. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCBv Harness (J23 - J231)v Harness (J43 - J432, J433)





CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Print a Service Page from Tray 1 to the Main Output



Go to step 6. The problem is solved. Verifythe original customer job printscorrectly.

6. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output




7. Check the Gear Drive:a. Power off the printer.b. Check for damage in the Gear Drive Asm. by

rotating the Main Motor.


Go to step 8 on page 165. Repair/replace the Gear DriveAsm.





to the Fuser Asm to make sure that it is correctlyconnected and not damaged.


Go to step 9. Repair/replace the Harness(J27, J11, J262-J271).

9. Check the Paper Handling Asm:a. Inspect the Paper Handling Asm for damaged parts,

especially the registration rollers.

Is the Paper Handling Asm damaged?

Replace the Paper HandlingAsm.

Go to step 10.

10. Check the BTR Support Asm:a. Inspect the BTR Support Asm for damaged parts,

especially the Bias Transfer Roll.

Is the BTR Support Asm damaged?

Replace the BTR Support Asm. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Aux Tray Asmv Env Tray Asm (if installed)






MAP 232: Paper Jam - Exit OnSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Exit Sensor is activated at anincorrect time or while not printing.


MCU PCB 5%

Harness (J27, J11, J262-J271) 5%

Interface PCB 3%


Table 34. Map 232: Paper Jam - Exit On


1. Check the Exit Sensor:

CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Check the paper path in the Fuser Asm for

obstructions.c. Open the paper jam customer access area at the

back of the fuser and check the Exit Sensor.

Is the Fuser and Exit Sensor clear of obstructions?

Go to step 2 on page 168. Clear the obstruction or replacethe Fuser.


Table 34. Map 232: Paper Jam - Exit On (continued)


2. Check the Exit Sensor Actuator:a. Power off the printer.b. Manually check the Exit Sensor Actuator and ensure

that it is not damaged and working correctly.c. Clean the Exit Sensor.

Is the Exit Sensor Actuator intact and workingcorrectly?

Go to step 3 on page 169. Repair/replace the Fuser Asm120 v, Fuser Asm 230 v.

CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutes forparts in this area to coolbefore handling.




3. Check the Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Open the Rear Cover and remove the Duplex Asm,

if it is installed.c. Run Diagnostic 1020 (see “Diagnostic Menu” on

page 284).d. Open the paper jam customer access area at the

back of the fuser and actuate the Exit Sensor byblocking the sensor.

CAUTION:<2-43> High Temperature; switch off the printerand allow at least 30 minutes for parts in thisarea to cool before handling.

Did the Diagnostic display “Sensor/Switch OK”when the Exit Sensor was blocked?

Repair/replace the MCU PCB Go to step 4 on page 170.







Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Fuser Asm 120 v, Fuser Asm

230 v

CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.

v Paper Handling Asmv MCU PCBv Interface PCBv Harness (J27, J11,

J262-J271)

Repair/replace the Harness(J27, J11, J262-J271).


MAP 250: Paper Jam - Duplex Early RegistrationSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Registration Sensor was activatedtoo early after the Duplex Sensor activation.

Duplex Asm 95%


MCU PCB 1%


1%

Table 35. Map 250: Paper Jam - Duplex Early Registration


1. Check the paper:a. Remove the paper in all trays, and reload with

fresh, dry paper.b. Run a test print.


Go to step 2 on page 172. The paper supply could be theproblem. Check the size andtype of the customer’s paperwith the specifications. If thepaper is within specification, usethe customer’s paper and repeatthis step.


Table 35. Map 250: Paper Jam - Duplex Early Registration (continued)


2. Check the paper path:a. Power off the printer.b. Check the paper path from the Duplex Asm to the

Registration Sensor for fragments of paper or otherforeign material that could block the paper path.


Bin in duplex mode (see “Printing the Service Page”on page 295.)




to the Duplex Asm to make sure that it is correctlyconnected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Paper Handling Asm



MAP 253: Paper Jam - Late DuplexSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Duplex Sensor was never activatedafter the Exit Sensor was activated.

Duplex Asm 80%

Exit Asm 18%

MCU PCB 1%

Harness (J34 - J341) 1%

Table 36. Map 253: Paper Jam - Late Duplex



fresh, dry paper.Note: The optional Face-up Output Bin must beclosed for duplex printing to occur. If the Face-upOutput Bin is open during duplex printing, errorcode 049 should occur.

b. Print a Service Page from Tray 1 to the Main OutputBin in duplex mode (see “Printing the Service Page”on page 295.)




Table 36. Map 253: Paper Jam - Late Duplex (continued)


2. Check the paper path:a. Power off the printer.b. Check the paper path from the Exit Sensor in the

Fuser Asm to the Duplex Asm for damaged parts orfragments of paper or other foreign material thatcould block the paper path.

c. Remove the Duplex Asm.d. Check the Duplex Asm, especially near the Duplex

Paper Photo Sensor, for foreign material ordamaged parts. Make sure the Duplex Asm isworking correctly.

e. Replace any damaged part.f. Print a Service Page from Tray 1 to the Main Output




3. Check the Harness (J34 - P341):1. Power off the printer.2. Check the Harness (J34 - P341) from the MCU

PCB to the Duplex Asm to make sure that it iscorrectly connected and not damaged.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Exit Asm

Repair/replace the Harness (J34- P341).


MAP 254: Paper Jam - Duplex OnSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Duplex Sensor was activated at anincorrect time (for example, at power on) or was not activatedin the specified time after the Exit Sensor was activated.

Duplex Asm 98%

MCU PCB 1%

Harness (J34 - P341) 1%

Table 37. Map 254: Paper Jam - Duplex On



fresh, dry paper.Note: The optional Face-up Output Bin must beclosed for duplex printing to occur. If the Face-upOutput Bin is open during duplex printing, errorcode 049 should occur.

b. Print a Service Page from Tray 1 to the Main OutputBin in duplex mode (see “Printing the Service Page”on page 295.)




Table 37. Map 254: Paper Jam - Duplex On (continued)


2. Check the paper path:a. Power off the printer.b. Check the paper path from the Exit Sensor in the

Fuser Asm to the Duplex Asm for damaged partsand for fragments of paper or other foreignmaterials that could block the paper path.

c. Remove the Duplex Asm.d. Check the Duplex Asm, especially in the jam

clearance customer access area, for foreignmaterial or damaged parts. Make sure the DuplexAsm is working correctly.

e. Replace any damaged parts.f. Print a Service Page from Tray 1 to the Main Output










MAP 255: Paper Jam - Duplex Late RegistrationSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Registration Sensor was neveractivated after the Duplex Sensor activation.

Duplex Asm 95%


MCU PCB 1%

Harness (J34 - P341) 1%

Table 38. Map 255: Paper Jam - Duplex Late Registration


1. Check the paper:a. Remove the paper from all trays and reload with






Table 38. Map 255: Paper Jam - Duplex Late Registration (continued)


2. Check the paper path:a. Power off the printer.b. Remove the Duplex Asm.c. Check the paper path from the Duplex Asm to the

Registration Sensor for fragments of paper or otherforeign materials that could block the paper path.

d. Open the jam clearance customer access area inthe Duplex Asm and check for foreign material ordamaged parts.

e. Replace any damaged part.f. Print a Service Page from Tray 1 to the Main Output







Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Paper Handling Asm



MAP 261: Paper Jam - Late OffsetSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Offset Exit Sensor was neveractivated after the Exit Sensor was when printing to theOffset Asm.

Offset Asm 90%

Exit Asm 5%


MCU PCB 1%

Harness (J35 - J351) 1%

Table 39. Map 261: Paper Jam - Late Offset



fresh, dry paper.b. Print a Service Page from Tray 1 to the Offset Bin

(see “Printing the Service Page” on page 295.)



2. Check the paper path:a. Power off the printer.b. Check the paper path from the Fuser Asm to the

Offset Exit for fragments of paper or other foreignmaterial that could block the paper path.

c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Offset Bin





Table 39. Map 261: Paper Jam - Late Offset (continued)


3. Check the Offset Exit Sensor Actuator:a. Power off the printer.b. Check the Offset Exit Sensor Actuator and ensure

that it is not damaged and working correctly.c. Clean the Offset Exit Sensor.

Is the Offset Exit Sensor Actuator intact andworking correctly?

Go to step 4. Repair/replace the Offset ExitSensor Actuator.

4. Check the Offset Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”


page 284).c. Actuate the Offset Exit Sensor by lifting the Offset

Exit Sensor Actuator.

Did the Diagnostic display “Sensor/Switch OK”when the Offset Exit Sensor was blocked?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asmv Fuser Asm 120 v, Fuser Asm

230 v


v Exit Asm



Table 39. Map 261: Paper Jam - Late Offset (continued)





Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB



MAP 262: Paper Jam - Offset OnSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Offset Exit Sensor was activated atthe wrong time.

Offset Asm 95%

MCU PCB 4%

Harness (J35 - J351) 1%

Table 40. Map 262: Paper Jam - Offset On



fresh, dry paper.b. Print a Service Page from Tray 1 to the Offset Bin





Offset Exit for fragments of paper or other foreignmaterial that could block the paper path.

c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Offset Bin





Table 40. Map 262: Paper Jam - Offset On (continued)


3. Check the Offset Exit Sensor Actuator:a. Power off the printer.b. Check the Offset Exit Sensor Actuator and ensure

that it is not damaged and working correctly.c. Clean the Offset Exit Sensor.

Is the Offset Exit Sensor Actuator intact andworking correctly?

Go to step 4. Repair/replace the Offset ExitSensor Actuator.

4. Check the Offset Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”


page 284).c. Actuate the Offset Exit Sensor by lifting the Offset

Exit Sensor Actuator.

Did the Diagnostic display “Sensor/Switch OK”when the Offset Exit Sensor was blocked?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asm

Go to step 5.




Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asm



MAP 272: Paper Jam - Exit On (Specific)Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Exit Sensor in the Fuser Asm wasactivated but did not deactivate within the specified time. Thiserror is the same as Error 276, but occurs from all papersexcept custom or universal.



Exit Motor 20%

Toner Cartridge 5%


BTR Support Asm 2%

Gear Drive Asm 1%

MCU PCB 1%

Interface PCB 1%

Harness (J27, J11, J262-J271) 1%

Harness (J23 - J231) 1%

Harness (J43 - J432, J433) 1%

Exit Roll 1 1%

Exit Roll 2 1%

Exit Roll 3 1%


Table 41. Map 272: Paper Jam - Exit On (Specific)


1. Check the paper:Note: This error can be generated by a brokenfull-stack sensor that causes paper to jam and block theExit Sensor in the Fuser. If the main bin is full of paperwhen error 272 occurs, go to “MAP 031: Unload PaperFrom Main Output Bin” on page 113. If the Offset Bin isfull of paper when error 272 occurs, go to “MAP 035:Unload Paper From Offset Bin” on page 115.a. Remove the paper from all trays, and reload with





2. Check the paper path:a. Power off the printer.b. Check the paper path from the Registration Sensor

to the Exit Asm for fragments of paper or otherforeign material that could block the paper path.






Table 41. Map 272: Paper Jam - Exit On (Specific) (continued)


3. Check the Registration Clutch:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Registration Clutch work correctly (make a‘click’ sound) when Diagnostic 1280 is run?



CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Print a Service Page from Tray 1 to the Main Output







Go to step 6 on page 187. The problem is solved. Verifythe original customer job printscorrectly.




6. Check the Gear Drive:a. Power off the printer.b. Open the Front Cover and remove the Toner

Cartridge.c. Open the Rear Cover.d. Check for damage in the Gear Drive Asm by

manually rotating the Main Motor clockwise andwatching the Gear Drive Asm.Note: The Gear Drive Asm will not engage thefuser gears if the front cover is open.

e. Check the gear that engages the gear on the FuserAsm to ensure that it is turning correctly.


Go to step 7. Repair/replace the Gear DriveAsm.

7. Check the Harness (J27, J11, J262-J271):a. Power off the printer.b. Check the Harness (J27, J11, J262-J271) from the

MCU PCB to the Fuser Asm to make sure that it iscorrectly connected and not damaged.





Is the Paper Handling Asm free of damage?

Go to step 9 on page 188. Replace the Paper HandlingAsm.




9. Check the BTR Support Asm:a. Remove the Bias Transfer Roll.b. Inspect the BTR Support Asm and the Bias Transfer

Roll for damaged parts


Replace the BTR Support Asm. Go to step 12 on page 189.



c. Check for continuity between the following pins:v J23-9 to J231-8





c. Remove the Paper Handling Asm. Then Check forcontinuity between the following pins:v J43-2 to J433-1v J43-1 to J433-4


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCBv 550-Sheet Tray Asmv Feed Asm





12. Check the Exit Rolls:a. Power off the printer.b. Open the Rear Cover.c. Manually turn the exit gears to ensure the exit gears

and rolls are working correctly.

Are the Exit Gears and Rolls working correctly?

Go to step 13. Replace the failing exit gear orexit roll.v Exit Roll 1v Exit Roll 2v Exit Roll 3

13. Check the Exit Motor:1. Power off the printer.2. Ensure that the harness from the Exit Motor to

P/J32 on the MCU PCB is correctly connected.3. Enter Service Mode (see “Accessing Service Mode”

on page 280.)4. Run Diagnostic 1150 (see “Diagnostic Menu” on

page 284).

Does the Exit Motor rotate and operate correctlywhen running this diagnostic?

Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Exit Motorv MCU PCB


MAP 275: Paper Jam - Early Exit OffSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected that the Exit Sensor in the Fuser Asmbecame deactivated too early after the paper entered theFuser.


Gear Drive Asm 24%

MCU PCB 15%

Harness (J27, J11, J262-J271) 1%

Table 42. Map 275: Paper Jam - Early Exit Off








Exit Asm for fragments of paper or other foreignmaterial that could block the paper path.






Table 42. Map 275: Paper Jam - Early Exit Off (continued)


3. Check the Gear Drive:a. Power off the printer.b. Remove the Gear Drive Asm.c. Check for damage by rotating the gears in the Gear

Drive Asm.






Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fuser Asm 120 v, Fuser Asm

230 v


v MCU PCB

Repair/replace the Harness(J27, J11, J262-J271).


MAP 276: Paper Jam - Exit On (Universal)Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Exit Sensor in the Fuser Asm wasactivated but did not deactivate within the specified time. Thiserror is the same as Error 272, but occurs only with customor universal paper sizes.



Exit Motor 20%

Toner Cartridge 5%


BTR Support Asm 2%

Gear Drive Asm 1%

MCU PCB 1%

Interface PCB 1%

Harness (J27, J11, J262-J271) 1%

Harness (J23 - J231) 1%

Harness (J43 - J432, J433) 1%


Table 43. Map 276: Paper Jam - Exit On (Universal)


1. Check the paper:Note: This error can be generated by a brokenfull-stack sensor that causes paper to jam and block theExit Sensor in the Fuser. If the main bin is full of paperwhen error 276 occurs, go to “MAP 031: Unload PaperFrom Main Output Bin” on page 113. If the Offset Bin isfull of paper when error 276 occurs, go to “MAP 035:Unload Paper From Offset Bin” on page 115.a. Remove the paper from all trays, and reload with





2. Check the paper path:a. Power off the printer.b. Check the paper path from the Registration Sensor

to the Exit Asm for fragments of paper or otherforeign material that could block the paper path.






Table 43. Map 276: Paper Jam - Exit On (Universal) (continued)


3. Check the Registration Clutch:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Does the Registration Clutch work correctly (make a‘click’ sound) when this diagnostic is run?



CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm.c. Print a Service Page from Tray 1 to the Main Output







Go to step 6 on page 195. The problem is solved. Verifythe original customer job printscorrectly.




6. Check the Gear Drive:a. Power off the printer.b. Open the Front Cover and remove the Toner

Cartridge.c. Check for damage by manually rotating the Main

Motor clockwise and watching the Gear Drive Asm.d. Check the gear that engages the gear on the Fuser

Asm to ensure that it is turning correctly











Go to step 9.

9. Check the BTR Support Asm:a. Remove the Bias Transfer Roll.b. Inspect the BTR Support Asm and the Bias Transfer

Roll for damaged parts


Replace the BTR Support Asm. Go to step 12 on page 196.











Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCBv 550-Sheet Tray Asmv Feed Asm


12. Check the Exit Motor:1. Enter Service Mode (see “Accessing Service Mode”

on page 280.)2. Run Diagnostic 1150 (see “Diagnostic Menu” on

page 284).

Does the Exit Motor rotate and operate correctlywhen running this diagnostic?

Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Exit Motorv MCU PCB


MAP 430: Motor ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a problem with the Main Motor. Main Motor 45%


Gear Drive Asm 5%

Toner Cartridge 5%


Feed Asm 5%


Aux Tray 5%

Env Tray Asm 5%


MCU PCB 4%

Harness (J28 - J281) 1%


Table 44. Map 430: Motor Error


1. Check the Main Motor:

a. Enter Service Mode (see “Accessing Service Mode” onpage 280.)

b. Run diagnostic 1100 (see “Diagnostic Menu” on page 284).Note: If you get error code 430 in the Diagnostic Menu andyou are unable to run the diagnostic, go to step 2 onpage 199.

Does the Main Motor turn continuously while the diagnosticis running?



Table 44. Map 430: Motor Error (continued)


2. Check the Main Motor:

DANGER

<1-10> Hazardous voltages are present. Do not touch thepins or the sockets of the power receptacle. Do notattempt to measure voltages or make any other checksat the power receptacle, the power cord, or the powersupply input before you perform the Power-ReceptacleSafety-Check. Make these checks only if you are aqualified service representative or a qualified electrician.Inform the customer if the voltages or other checks arenot within the correct operating range. Do not continueuntil the customer has fixed the problem.

a. Power off the printer.

b. Remove the Main Motor, leaving the Harness (J29 - J291)attached to the MCU PCB.


d. Enter Service Mode (see “Accessing Service Mode” onpage 280.)

e. Run diagnostic 1100 (see “Diagnostic Menu” on page 284).

f. If you get error code 430 in the Diagnostic Menu and youare unable to run the diagnostic, answer no to this step.

Does the Main Motor turn continuously while the diagnosticis running?

Go to step 3 on page 200. Repair/replace the following, oneat a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)

v Main Motor

v MCU PCB




3. Check the Gear Drive:

a. Power off the printer.

b. Re-install the Main Motor.

c. Remove the Envelope Tray Asm if it is installed.

d. Remove the printer from the Optional Paper Drawers (Tray2, Tray 3) if they are installed.

CAUTION:

<2-41> The printer weighs approximately 28 kg (62 lb). Use two personsto carry the printer. Use appropriate lifting precautions.

hcsf

0241

e. Open the front cover and remove the toner cartridge.

f. Check for damage by manually rotating the Main Motorclockwise and watching the Gear Drive Asm.


Reinstall the Gear Drive Asm. Goto step 4.


4. Check the Toner Cartridge:

a. Replace the Toner Cartridge.

b. Enter Service Mode (see “Accessing Service Mode” onpage 280.)

c. Print a Service Page from Tray 1 to the Main Output Bin(see “Printing the Service Page” on page 295.)

Does error code 430 recur?

Go to step 5 on page 201. Replacing the Toner Cartridgefixed the problem. Verify theoriginal customer job printscorrectly.




5. Check the Fuser Asm:

CAUTION:<2-43> High Temperature; switch off the printer and allowat least 30 minutes for parts in this area to cool beforehandling.1. Power off the printer.

2. Replace the Fuser Asm 120 v, Fuser Asm 230 v.

3. Power on the printer and print a Service Page from Tray 1to the Main Output Bin (see “Printing the Service Page” onpage 295.)

Does error code 430 recur?

Repair/replace the following, oneat a time. After eachreplacement, check to see if theproblem has been fixed.

v Feed Asm

v Paper Handling Asm

v Aux Tray

v Env Tray Asm (if installed)

v Option Paper Drawer (ifinstalled)

Replacing the Fuser Asm fixedthe problem. Verify the originalcustomer job prints correctly.


MAP 451: Fan ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a problem with the Fan Motor. Fan Motor 75%

MCU PCB 10%


Harness (J28 - J281) 5%

Table 45. Map 451: Fan Error


1. Check the Fan Motor:a. Power off the printer.b. Power on the printer.

Does the Fan Motor turn at any time?


2. Check the Fan Motor Harness:a. Power off the printer.b. Check the Fan Motor Harness J283 from the LVPS



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fan Motorv LVPS 120V, LVPS 230V

Replace the Fan Motor.


Table 45. Map 451: Fan Error (continued)





Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fan Motorv MCU PCBv LVPS 120V, LVPS 230V



MAP 454: Fuser ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a problem with the Fuser Asm. Fuser Asm 120 v, Fuser Asm 230 v 75%

MCU PCB 10%


Harness (J27, J11, J262-J271) 4%

Harness (J28 - J281) 1%

Table 46. Map 454: Fuser Error



CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Power on the printer.


Go to step 2 on page 205. The problem is fixed. Verify theoriginal customer job printscorrectly.


Table 46. Map 454: Fuser Error (continued)


2. Check the Harness (J27, J11, J262 - J271):a. Power off the printer.b. Check the Harness (J27, J11, J262 - J271) from the

MCU PCB to the LVPS and Fuser Connector tomake sure that it is correctly connected and notdamaged.


Go to step 3. Repair/replace the Harness(J27, J11, J262-J271)




Repair/replace the following:v LVPS 120V, LVPS 230Vv MCU PCB



MAP 460: Offset ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Offset Direction Solenoid in theOffset Asm failed.

Offset Direction Solenoid (Offset Asm) 85%

MCU PCB 10%

Harness (J35 - J351) 5%

Table 47. Map 460: Offset Error


1. Is an Offset Asm installed on this printer? Go to step 2. Replace the MCU PCB.





3. Has the Offset Asm already been replaced oncebecause of this problem? If you are not sure, answerno.

Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB


MAP 511: Laser ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a problem with the ROS Asm (Laser). ROS Asm (Laser) 70%

MCU PCB 10%

Toner Cartridge Key Sensor 10%


Harness (J21 - J211, J212, J213) 3%

Harness (J22 - J223) 2%

Table 48. Map 511: Laser Error


1. Check the ROS Asm (Laser):a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Run diagnostic 1110 (see “Diagnostic Menu” on

page 284).c. Listen for the ROS Motor to start to rotate.d. If you are unable to run the diagnostic, go to step 2

on page 208.

Does the ROS Motor rotate while the diagnostic isrunning?



Table 48. Map 511: Laser Error (continued)


2. Check the ROS harnesses:a. Power off the printer.b. Remove the ROS Asm (Laser).c. Check the Harness (J21 - J211, 212, 213) and

Harness (J22 - J223) to make sure they aresecurely fastened to the ROS Asm (Laser):

d. Check the harnesses for any damage.

Are the harnesses free of damage and in goodcondition?

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCB

Repair/replace the Harness:v Harness (J21 - J211, J212,

J213)v Harness (J22 - J223)

3. The problem could be a defective Toner Cartridge KeySensor.a. Power off the printer.b. Check the Harness (J25 - J251) from the MCU PCB

to the Toner Cartridge Key Sensor for any damage.

Is the harness free of damage and in goodcondition?

Go to step 3. Repair/replace the Harness (J25- J251)

4. Check the ROS harnesses:1. Power off the printer.2. Remove the ROS Asm (Laser).3. Check the Harness (J21 - J211, 212, 213) and

Harness (J22 - J223) to make sure they aresecurely fastened to the ROS Asm (Laser):

4. Check the harnesses for any damage.

Are the harnesses free of damage and in goodcondition?

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv LVPS 120V, LVPS 230Vv Toner Cartridge Key Sensor

Repair/replace the Harness:v Harness (J21 - J211, J212,

J213)v Harness (J22 - J223)


MAP 623: Data ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a data underrun or overrun on thecurrent page being processed. By pressing enter, the printeraborts the current page and starts processing the next page.

Controller PCB 50%

NIC 50%

Table 49. Map 623: Data Error


1. This error is most likely caused by the computersending data to the printer. Either evaluate thatcomputer by printing to other sources, change the driverused, or contact your next level of support.

Is the computer working and sending pagescorrectly?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv NIC

The problem lies within thecomputer sending data to theprinter.


MAP 630: NVM ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected a problem with the NVRAM on theMCU.

MCU PCB 100%

Table 50. Map 630: NVM Error


1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”

on page 280.)

Do you still have an error code 630?

Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.

2. Check the NVRAM settings:1. Enter the Factory Adjustments Menu (see “Factory

Adjust Menu” on page 288).2. Check the parameters for each value in the Factory

Adjustments.3. If you can’t enter the Service Mode, replace the

MCU PCB.

Are all parameters set correctly? If unsure, set todefaults and retest.

Replace the MCU PCB. Enter the correct parameters. Ifthe problem recurs, replace theMCU PCB.


MAP 631: NVRAM ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with the NVRAM on theController PCB.

Controller PCB 100%

Table 51. Map 631: NVRAM Error


1. Reset the printer.1. Power off the printer.2. Wait two minutes.3. Enter Service Mode (see “Accessing Service Mode”

on page 280.)


Replace the Controller PCB. The problem appears to beintermittent. If the problemrecurs, replace the ControllerPCB.


MAP 650: Service ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Service Port failed. MCU PCB 95%

Service Cable 5%

Table 52. Map 650: Service Error


1. Are you attempting to use the Service Port inService Mode?

Go to step 2. The Service Port is onlydesigned for use in ServiceMode. Do not use this port forany other reason.

2. Check the Service Cable:a. Check the connections on the Service Cable.

Is the Service Cable in good condition and correctlyconnected?

Go to step 3. Repair/replace the ServiceCable.

3. There appears to be a hardware problem with theService Port. Do not replace the MCU PCB unlessother problems occur. Use the Operator Panel toaccess the Service Mode.


MAP 651: Boot ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with the boot file on theCompact Flash.

Compact Flash 80%

Controller PCB 20%

Table 53. Map 651: Boot Error



on page 280.)



The problem appears to beintermittent. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Compact Flashv Controller PCB


MAP 652: Memory ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with the Memory DIMM. Memory DIMM 80%

Controller PCB 20%

Table 54. Map 652: Memory Error



on page 280.)




2. Check the Memory DIMM:

Is there more than one Memory DIMM installed inthis printer?

Go to step 3 on page 215. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Memory DIMMv Controller PCB.


Table 54. Map 652: Memory Error (continued)


3. Check the Memory DIMMs:1. Power off the printer.2. Remove each Memory DIMM, one at a time, to see

if a single Memory DIMM is causing the problem.3. After each removal, power on the printer.

Is the problem caused by only one Memory DIMM?

Replace the failing MemoryDIMM

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCB.v Both Memory DIMMs.


MAP 653: File ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with the file system onthe Compact Flash.

Compact Flash 80%

Controller PCB 20%

Table 55. Map 653: File Error



on page 280.)





MAP 654: HW Error (MCU)Symptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with MCU communication. MCU PCB 60%

Controller PCB 35%


Harness (J28 - J281) 1%

Table 56. Map 654: HW Error (MCU)



on page 280.)



2. Check the connection:a. Power off the printer.b. Check the connection between the MCU PCB and

the Controller PCB. Reseat this connection.c. Power on the printer.


Go to step 3 on page 218. The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v MCU PCBv Controller PCB


Table 56. Map 654: HW Error (MCU) (continued)




3. Check for continuity between the following pins:v PJ28-10 to PJ281-10


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv LVPS 120V, LVPS 230Vv Controller PCB



MAP 661: Firmware ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with its code. Controller PCB 99%

Infoprint 21 code 1%

Table 57. Map 661: Firmware Error



on page 280.)



2. Check the code:a. Power off the printer.b. Install a new Compact Flash or download new code,

if possible.c. Power on the printer.


Go to step 3. The problem appears to beisolated to the original code. Ifthe problem recurs, go to step3.

3. Check the Controller PCB:1. Power off the printer.2. Install a new Controller PCB.3. Power on the printer.


Contact your next level ofsupport.

The problem appears to beisolated to the broken ControllerPCB. If the problem recurs,contact your next level ofsupport.


MAP 671: Disk ErrorSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a problem with the Hard Drive Hard Drive 90%

Controller PCB 10%

Table 58. Map 671: Disk Error



on page 280.)



2. Check the connection:1. Power off the printer.2. Check the connection between the Hard Drive and

the Controller PCB. Reseat this connection.3. Power on the printer.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Hard Drivev Controller PCB

The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Hard Drivev Controller PCB


MAP 699: HW Error (Offset)Symptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected that the Offset Circuitry failed. MCU PCB 85%

Offset Asm 10%

Harness (J35 - J351) 5%

Table 59. Map 699: HW Error (Offset)






2. Is an Offset Asm installed on this printer? Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asm.v MCU PCB

Replace the MCU PCB.


MAP 714: Duplex ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Duplex Asm failed. Duplex Asm 85%

MCU PCB 10%


5%

Table 60. Map 714: Duplex Error


1. Is a Duplex Asm installed on this printer? Go to step 2. Replace the MCU PCB.





3. Has the Duplex Asm already been replaced oncebecause of this problem? If you are unsure, answerno.

Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB


MAP 772: ENV ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Env Tray Asm failed. Env Tray Asm 85%

MCU PCB 10%

Interface PCB 5%

Harness (J23 - J231) 3%

Env Connector - Female 2%

Table 61. Map 772: ENV Error


1. Is an Env Tray Asm installed on this printer? Go to step 2. Replace the MCU PCB.






Table 61. Map 772: ENV Error (continued)


3. Check the Env Connector -Female:a. Power off the printer.b. Remove the Env Tray Asm.c. Check the Env Connector -Female to make sure

that it is correctly connected to the Interface PCBand not damaged.

Is the connector correctly connected and notdamaged?

Go to step 4. Repair/replace the EnvConnector - Female.

4. Has the Env Tray Asm already been replaced oncebecause of this problem? If unsure, answer no.

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem has been fixed.v MCU PCBv Interface PCBv Env Connector - Female

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Env Connector - Female


MAP 795: Offset ErrorSymptom Explanation Suspected FRUs/Causes Probability

MCU Logic detected the Offset Direction Solenoid failed. Offset Asm 85%

MCU PCB 10%

Harness (J35 - J351) 5%

Table 62. Map 795: Offset Error


1. Is an Offset Asm installed on this printer? Go to step 2. Replace the MCU PCB.

2. Check the Harness (J35 - J351):a. Power off the printer.b. Remove the Offset Asm.c. Check the Harness (J35 - J351) from the MCU PCB

to the connector that the Offset Asm connects toand make sure that it is correctly connected and notdamaged.


Go to step 3. Repair/replace the following:v MCU PCBv Harness (J35 - J351).

3. Has the Offset Asm already been replaced oncebecause of this problem? If unsure, answer no.

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Harness (J35 - J351).

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCBv Harness (J35 - J351).


MAP 821: PS OptionSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB detected a problem with the FontsCompact Flash.

Font Flash 70%

Controller PCB 30%

Table 63. Map 821: PS Option


1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.

Do you still have a 821 error?


2. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.

Do you still have the error?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Font Flashv Controller PCB

Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Font Flashv Controller PCB


MAP 831: Controller Loop TrapSymptom Explanation Suspected FRUs/Causes Probability

Controller logic detected a portion of code was stuck in aloop. This error triggers after five minutes.

Options 80%

Controller PCB 19%

Infoprint 21 code 1%

Table 64. Map 831: Controller Loop Trap



on page 280.)d. Wait five minutes.



2. Check the options:a. Power off the printer.b. Remove the options, one at a time, including

Controller options. Power on after each removal,and wait five minutes to check to see if the optioncaused the problem.

Did removing one of the options stop the error code831?

Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Problem option.v Controller PCB.

If the problem recurs, go tostep 3.

Replace the Controller PCB. Ifthe problem recurs, go to step3.

3. The problem could be with the Infoprint 21 code. Contact your next level of support.


MAP 851: IPDS OptionSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB detected a problem with the IBMAFP/IPDS Module.


Controller PCB 30%

Table 65. Map 851: IPDS Option







Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v IBM AFP/IPDS Modulev Controller PCB

Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v IBM AFP/IPDS Modulev Controller PCB


MAP 852: IPDS Add MemSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB does not have enough memory toprocess the IPDS job.

Memory DIMM 40%

Controller PCB 30%


Table 66. Map 852: IPDS Add Mem


1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.d. Print the customer job.



2. Check the installed memory:a. Print a Service Page from Tray 1 to the Main Output

Bin (see “Printing the Service Page” on page 295.)b. Look at the ″Installed Memory″ on the printed

Service Page.

Does the memory listed match the memory installedin the Controller PCB?



Table 66. Map 852: IPDS Add Mem (continued)


3. Check the installed memory:a. Power off the printer.b. Remove all memory DIMMs.c. Check the memory DIMMs by putting one in the

printer.d. Power on the printer.e. Print a Service Page from Tray 1 to the Main Output

Bin (see “Printing the Service Page” on page 295.)f. Verify the amount of memory on the Service Page

matches the amount of memory in the printer.g. Repeat for all memory DIMMs.

Does the memory listed match the memory installedin the Controller PCB for all DIMMs?

Problem solved. Repair/replace the following,one at a time. After eachreplacement check to see if theproblem has been fixed.v Failing Memory DIMMv Controller PCB



Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv IBM AFP/IPDS Module

Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement check to seeif the problem has been fixed.v Controller PCBv IBM AFP/IPDS Module


MAP 853: IPDS Low MemSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB detected a problem with the IBMAFP/IPDS Module.


Controller PCB 30%

Table 67. Map 853: IPDS Low Mem




Go to step 2. This problem could beintermittent. If the problemrecurs, go to step 2.






MAP 854: IPDS ErrorSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB detected a problem with the IPDS Fonts. IBM AFP/IPDS Module 70%

Controller PCB 30%

Table 68. Map 854: IPDS Error




Go to step 2. This problem could beintermittent. If the problemrecurs, go to step 2.






MAP 860: No CX Host SyncSymptom Explanation Suspected FRUs/Causes Probability

The Coax NIC detected a problem between itself and thehost computer.

Coax NIC 50%

Host Computer 50%

Table 69. Map 860: No CX Host Sync



on page 280.)


Replace the Coax NIC. If theproblem recurs, go to step 2.

The problem appears to beintermittent. If the problemrecurs, go to step 2.

2. The problem seems to be with the Host Computer. Verify correct host computer operation or call your next level of support.


MAP 861: No TX Host SyncSymptom Explanation Suspected FRUs/Causes Probability

The Twinax NIC detected a problem between itself and thehost computer.

Twinax NIC 50%

Host Computer 50%

Table 70. Map 861: No TX Host Sync



on page 280.)


Replace the Twinax NIC. If theproblem recurs, go to step 2.


2. The problem seems to be with the Host Computer. Verify correct host computer operation or call your next level of support.


MAP 862: CX Key RequestSymptom Explanation Suspected FRUs/Causes Probability

The Coax NIC detected a missing key between itself and thehost computer.

Coax NIC 50%

Host Computer 50%

Table 71. Map 862: CX Key Request



on page 280.)


Replace the Coax NIC. If theproblem recurs, go to step 2.


2. The problem seems to be with the host computer. Verify correct host computer operation or call your next level of support.


MAP 872: Network OptionSymptom Explanation Suspected FRUs/Causes Probability

The Controller PCB detected a problem between itself andthe Coax or Twinax NIC Card.

Coax NIC 50%

Controller PCB 50%

Table 72. Map 872: Network Option



on page 280.)



2. Check the connection:1. Power off the printer.2. Check the connection between the NIC and the

Controller PCB. Reseat this connection.3. Power on the printer.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v NIC Cardv Controller PCB

The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v NIC Cardv Controller PCB


MAP 900: Background or Dark ImageSymptom Explanation Suspected FRUs/Causes Probability

There is toner contamination on all or part of the page. Thecontamination can vary from a very light gray dusting to avery dark print.

Toner Cartridge 80%

HVPS 10%

BTR Support Asm 4%

Bias Transfer Roll 1%


Harness (J26 - J261) 1%

MCU PCB 1%

Controller PCB 1%

ROS Asm (Laser) 1%

Table 73. Map 900: Background or Dark Image


1. Check the density setting:a. Check the density setting in the Config Menu to

ensure that it is set at the default value of 3.b. Print a Service Page from Tray 1 to the Main Output


Is there still background on the print?

Go to step 2 on page 238. The problem could beintermittent. Verify that theoriginal job prints correctly.


Table 73. Map 900: Background or Dark Image (continued)


2. Check the printer:a. Enter Service Mode (see “Accessing Service Mode”


page 284).

Is there background on this print?

Go to step 3. The problem is not with theprinter. Repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Controller PCBv MCU PCB



Is there still background on the print?

Go to step 4. Problem solved. Verify theoriginal job prints correctly.

4. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm

to ensure good contact with the Toner Cartridge.

Are the metal contacts intact and not deformed orcontaminated?

Go to step 5. Reform, clean, or replace thecontacts on the BTR SupportAsm.

5. Check the Bias Transfer Roll:a. Inspect the Bias Transfer Roll.

Is the Bias Transfer Roll intact and notcontaminated?

Go to step 6 on page 239. Clean or replace the BiasTransfer Roll.


Table 73. Map 900: Background or Dark Image (continued)


6. Check the Harness (J26 - J261):a. Power off the printer.b. Check the harness from the MCU PCB to the

HVPS.

Is the harness loose, damaged or disconnected?

Repair/replace the Harness (J26- J261) as necessary.

Go to step 7.

7. Repair/replace the following, one at a time. After eachreplacement, determine if the problem is fixed byprinting a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm 230 v

CAUTION:<2-43> High Temperature; switch off the printerand allow at least 30 minutes for parts in thisarea to cool before handling.

v HVPSv MCU PCBv ROS Asm (Laser)


MAP 905: All Black PrintSymptom Explanation Suspected FRUs/Causes Probability

The entire printed page is black. Toner Cartridge 50%

HVPS 40%

BTR Support Asm 5%

ROS Asm (Laser) 2%

Harness (J26 - J261) 1%

MCU PCB 1%

Controller PCB 1%

Table 74. Map 905: All Black Print




page 284).

Is the print completely black?

Go to step 2. The problem is not with theprinter. Repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Controller PCBv MCU PCB



Is the print still completely black?

Go to step 3 on page 241. Problem solved. Verify theoriginal job prints correctly.


Table 74. Map 905: All Black Print (continued)


3. Check the ROS Asm:a. Power off the printer.b. Remove the ROS Asm (Laser).c. Use a sheet of paper to cover the laser window on

the ROS Asm.d. Reinstall the ROS Asm (Laser).e. Print a Service Page from Tray 1 to the Main Output


Is the print still completely black?

Go to step 4. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB





5. Check the Harness (J26 - J261):1. Power off the printer.2. Check the harness from the MCU PCB to the

HVPS.3. Test for continuity between:v PJ26-14 and PJ261-14



Replace the HVPS.


MAP 910: All Blank PrintSymptom Explanation Suspected FRUs/Causes Probability

The entire printed page is blank. Toner Cartridge 70%

HVPS 20%

BTR Support Asm 3%


Harness (J26 - J261) 1%


MCU PCB 1%

Controller PCB 1%

ROS Asm (Laser) 1%

Harness (J22 - J223) 1%

Table 75. Map 910: All Blank Print


1. Check the density setting:a. Check the DENSITY item in the Config Menu to



Is the print still completely blank?



Table 75. Map 910: All Blank Print (continued)




page 284).Note: This diagnostic produces a test print thatdoes not use the Controller PCB.








and ensure good contact with the Toner Cartridge.



5. Check the ROS Asm:a. Remove the ROS Asm (Laser).b. Check the laser window for contamination that could

be blocking the laser beam.

Is the laser window clean?

Go to step 6 on page 244. Clean the laser window orreplace the ROS Asm (Laser).


Table 75. Map 910: All Blank Print (continued)




Go to step 7. Clean or replace the BiasTransfer Roll.

7. Check the Harness (J26 - J261):a. Power off the printer.b. Check the harness from the MCU PCB to the

HVPS.



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv LVPS 120V, LVPS 230Vv ROS Asm (Laser)v MCU PCBv Controller PCB

8. Check the Harness (J22 - J223):1. Power off the printer.2. Check the harness from the MCU PCB to the ROS

Asm (Laser).



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Controller PCBv MCU PCB


MAP 920: Damaged PageSymptom Explanation Suspected FRUs/Causes Probability

The page is bent, wrinkled, creased or torn. Toner Cartridge 50%





Feed Asm 2%

Exit Asm 2%

Table 76. Map 920: Damaged Page





Aux Tray.d. Determine which trays are damaging paper.

Is the print still damaged?

Go to step 2. The problem might be with thecustomer job. Verify the originaljob prints correctly.

2. Are all trays damaging paper? Go to step 6 on page 247. Go to step 3 on page 246.


Table 76. Map 920: Damaged Page (continued)


3. Check the paper path for the tray with the problem:a. Check the paper path in the tray for fragments of

paper. Replace any worn, contaminated, or brokenparts.

b. Print a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)



4. Check the paper path:a. Check the paper path in all location areas for

fragments of paper. Replace any worn,contaminated, or broken parts.


Is the print still skewed?







Table 76. Map 920: Damaged Page (continued)


6. Check the Bias Transfer Roll:1. Power off the printer.2. Remove the Bias Transfer Roll3. Inspect the Bias Transfer Roll.


Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Fuser Asm 120 v, Fuser Asm

230 v


v Feed Asmv 550-Sheet Tray Asmv Paper Handling Asmv Exit Asm

Clean or replace the BiasTransfer Roll.


MAP 930: Not Fused or Partially Fused ImageSymptom Explanation Suspected FRUs/Causes Probability

The image on the printed page is not completely fused (thetoner easily rubs off). If the print also has light density, correctthis first (see “MAP 935: Light Image” on page 250).


MCU PCB 20%


Table 77. Map 930: Not Fused or Partially Fused Image


1. Check the paper:a. Ask the customer about the type of paper and input

tray that is having the fusing problem.b. Load fresh, dry paper of the type that has been

failing in the tray the customer was using.c. Print a Service Page from that tray (see “Printing

the Service Page” on page 295.)d. Check the fusing quality on the print.

Is the image fused correctly?

The problem is with the papersupply or customer job. If theoriginal job does not printcorrectly, go to step 2 onpage 249.



Table 77. Map 930: Not Fused or Partially Fused Image (continued)


2. Check the Media Type:1. Check the Tray Type setting in the Paper Menu in

the Operator Panel for the tray with the problem toensure that it is correct.

Is the setting of Media Type correct?

Set the Media Type to thecorrect setting.

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm

230 v


v MCU PCBv LVPS 120V, LVPS 230V


MAP 935: Light ImageSymptom Explanation Suspected FRUs/Causes Probability

The image is light. Toner Cartridge 70%


HVPS 4%

BTR Support Asm 1%


MCU PCB 1%

ROS Asm (Laser) 1%

Harness (J26 - J261) 1%


Table 78. Map 935: Light Image


1. Check the density setting:a. Check the density setting in the Config Menu to



Is the print still light?

Go to step 2 on page 251. The problem could beintermittent. Verify that theoriginal job prints correctly.


Table 78. Map 935: Light Image (continued)




Is the print still light?









5. Check the ROS Asm:a. Remove the ROS Asm (Laser).b. Check the laser window for contamination that could

be blocking the laser beam.

Is the laser window clean?

Go to step 6 on page 252. Clean the laser window orreplace the ROS Asm.


Table 78. Map 935: Light Image (continued)



HVPS.



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv BTR Support Asmv Fuser Asm 120 v, Fuser Asm

230 v


v MCU PCBv ROS Asm (Laser)v LVPS 120V, LVPS 230Vv Controller PCBv Feed Asm


MAP 940: Image RegistrationSymptom Explanation Suspected FRUs/Causes Probability

The image is not correctly positioned on the page. If theimage is not parallel with the edges of the page, see “MAP950: Skewed Image” on page 260).

Toner Cartridge 30%



Feed Asm 10%


MCU PCB 1%

Controller PCB 1%

ROS Asm (Laser) 1%

Table 79. Map 940: Image Registration





Aux Tray. (see “Printing the Service Page” onpage 295.)

d. Determine which trays are having a registrationproblem.

Is the print registration still bad?



Table 79. Map 940: Image Registration (continued)


2. Are all trays having the registration problem? Go to step 6 on page 255. Go to step 3.

3. Check the registration settings:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Change all registration settings to their defaults. See

“Factory Adjust Menu” on page 288.c. Print a Service Page from Tray 1 to the Main Output


Is the print still misregistered?


4. Check the Feed Asm for the tray with the registrationproblem:a. Power off the printer.b. Inspect the Feed Asm for damaged parts.

Is the Feed Asm damaged?

Replace the Feed Asm. Go to step 5.

5. Check the 550-Sheet Tray Asm for the tray with theregistration problem:a. Inspect the 550-Sheet Tray Asm for damaged parts.

Is the 550-Sheet Tray Asm damaged?

Replace the 550-Sheet TrayAsm.



Table 79. Map 940: Image Registration (continued)


6. Check the Registration Clutch - Electric:a. Enter Service Mode (see “Accessing Service Mode”


page 284).c. Listen for a click from the registration clutch when

the diagnostic is run, and a second clickapproximately one half second later.

Does the Registration Clutch - Electric clickcorrectly when the diagnostic is run?

Go to step 7. Replace the Registration Clutch- Electric.

7. Check the Paper Handling Asm:a. Power off the printer.b. Inspect the Paper Handling Asm for damaged parts,




Go to step 8.

8. Replace the Toner Cartridge:1. Replace the Toner Cartridge.2. Print a Service Page from Tray 1 to the Main Output


Is the print still misregistered?

Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB

Problem solved. Verify theoriginal job prints correctly.


MAP 941: Repeating Spots or VoidsSymptom Explanation Suspected FRUs/Causes Probability

There are spots or voids on the page that repeat at regularintervals.

Toner Cartridge 80%



ROS Asm (Laser) 3%

MCU PCB 1%

Controller PCB 1%

Table 80. Map 941: Repeating Spots or Voids





Aux Tray.

Does the print still have spots or voids?







Table 80. Map 941: Repeating Spots or Voids (continued)


3. Check the Bias Transfer Roll:a. Power off the printer.b. Remove the Bias Transfer Roll and inspect it for

damage and contamination.


Go to step 4. Replace the Bias Transfer Roll.

4. Check the ROS Asm (Laser):1. Power off the printer.2. Remove the ROS Asm (Laser).3. Inspect the laser window for contamination or

anything else that would block the laser path.4. Reinstall the ROS Asm (Laser).5. Print a Service Page from Tray 1 to the Main Output




230 v


v ROS Asm (Laser)v MCU PCBv Controller PCB



MAP 945: Residual or Ghost ImagesSymptom Explanation Suspected FRUs/Causes Probability

The printed page contains random light ghost images. Theimages may either be from a previous page or the currentpage.

Toner Cartridge 70%



Table 81. Map 945: Residual or Ghost Images


1. Check the paper supply:a. Replace the paper with fresh, dry standard paper.b. Print the problem image or a Service Page from

Tray 1 to the Main Bin (see “Printing the ServicePage” on page 295.)

Does the print still contain ghost images?




Does the print still contain ghost images?



Table 81. Map 945: Residual or Ghost Images (continued)


3. Check the Bias Transfer Roll:1. Power off the printer.2. Inspect the Bias Transfer Roll.


Replace the Fuser Asm 120 v,Fuser Asm 230 v.




MAP 950: Skewed ImageSymptom Explanation Suspected FRUs/Causes Probability

The image on the printed page is not parallel with the edgesof the page. If the image is not positioned correctly on thepage, see “MAP 940: Image Registration” on page 253).

Toner Cartridge 30%


Feed Asm 20%


MCU PCB 1%

Controller PCB 1%

ROS Asm (Laser) 1%

Table 82. Map 950: Skewed Image





Aux Tray (see “Printing the Service Page” onpage 295.)

d. Determine which trays are having a registrationproblem.



2. Are all trays having the skew problem? Go to step 6 on page 261. Go to step 3 on page 261.


Table 82. Map 950: Skewed Image (continued)


3. Check the paper path for the tray with the skewproblem:a. Check the paper path in the tray for fragments of

paper. Replace any worn, contaminated, or brokenparts.




4. Check the Feed Asm for the tray with the skewproblem:a. Power off the printer.b. Inspect the Feed Asm for damaged parts. Install

new Feed, Pick, and Retard rollers if they are worn.

Is the Feed Asm damaged?

Replace the Feed Asm. Go to step 5.

5. Check the 550-Sheet Tray Asm for the tray with theskew problem:a. Inspect the 550-Sheet Tray Asm for damaged parts.

Is the 550-Sheet Tray Asm damaged?

Replace the 550-Sheet TrayAsm.

Go to step 6.

6. Check the paper path:a. Check the paper path in all location areas for

fragments of paper. Replace any worn,contaminated, or broken parts.





Table 82. Map 950: Skewed Image (continued)


7. Check the Paper Handling Asm:a. Power off the printer.b. Inspect the Paper Handling Asm for damaged parts,




Go to step 8.

8. Replace the Toner Cartridge:1. Replace the Toner Cartridge.2. Print a Service Page from Tray 1 to the Main Output



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB



MAP 955: Spots on PrintsSymptom Explanation Suspected FRUs/Causes Probability

There are spots of toner randomly scattered on the print sideof the page.

Toner Cartridge 80%



BTR Support Asm 1%

ROS Asm (Laser) 1%

MCU PCB 1%

Controller PCB 1%

Table 83. Map 955: Spots on Prints




Are there still spots on the print?


2. Check the Bias Transfer Roll:a. Power off the printer.b. Inspect the Bias Transfer Roll.




Table 83. Map 955: Spots on Prints (continued)


3. Check the Toner Cartridge contacts:1. Remove the Toner Cartridge.2. Inspect the metal contacts on the BTR Support Asm




230 v


v ROS Asm (Laser)v MCU PCBv LVPS 120V, LVPS 230V

Reform, clean, or replace thecontacts on the BTR SupportAsm.


MAP 965: Horizontal StreaksSymptom Explanation Suspected FRUs/Causes Probability

There are black lines running horizontally across the page. Toner Cartridge 50%


HVPS 20%


BTR Support Asm 1%

ROS Asm (Laser) 1%

MCU PCB 1%

Controller PCB 1%

Table 84. Map 965: Horizontal Streaks




Are there still lines on the page?



Table 84. Map 965: Horizontal Streaks (continued)


2. Check the ROS Asm:a. Power off the printer.b. Use a sheet of paper to cover the laser window on

the toner cartridge.c. Print a Service Page from Tray 1 to the Main Output



Go to step 3. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB





Table 84. Map 965: Horizontal Streaks (continued)


4. Check the Toner Cartridge contacts:1. Remove the Toner Cartridge.2. Inspect the metal contacts on the BTR Support Asm



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv Fuser Asm 120 v, Fuser Asm

230 v


Reform, clean, or replace thecontacts on the BTR SupportAsm.


MAP 970: Vertical StreaksSymptom Explanation Suspected FRUs/Causes Probability

There are black lines running vertically along the page. Toner Cartridge 50%



HVPS 2%

MCU PCB 1%

Controller PCB 1%

Table 85. Map 970: Vertical Streaks






2. Check the ROS Asm:a. Power off the printer.b. Use a sheet of paper to cover the laser window on

the toner cartridge.c. Print a Service Page from Tray 1 to the Main Output



Go to step 3 on page 269. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v MCU PCBv Controller PCB


Table 85. Map 970: Vertical Streaks (continued)


3. Check the Bias Transfer Roll:1. Power off the printer.2. Inspect the Bias Transfer Roll.



230 v


v HVPS



MAP 975: Voids on PrintsSymptom Explanation Suspected FRUs/Causes Probability

There are small areas of the image on the printed page thatare extremely light or missing completely.

Toner Cartridge 50%



Harness (J26 - J261) 1%

HVPS 1%

ROS Asm (Laser) 1%

MCU PCB 1%

Controller PCB 1%

Table 86. Map 975: Voids on Prints





Aux Tray.

Does the print still have voids?



Table 86. Map 975: Voids on Prints (continued)










Do the voids occur regularly at intervals around61mm (2.4 in)?





Table 86. Map 975: Voids on Prints (continued)



HVPS.3. Test for continuity between:v PJ26-5 and PJ261-5v PJ26-9 and PJ261-9v PJ26-12 and PJ261-12



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv ROS Asm (Laser)v MCU PCBv Controller PCB


MAP 980: Horizontal VoidsSymptom Explanation Suspected FRUs/Causes Probability

There are horizontal bands on the printed page that areextremely light or missing entirely.

Toner Cartridge 50%


Gear Drive Asm 10%


BTR Support Asm 1%

Harness (J26 - J261) 1%

HVPS 1%

ROS Asm (Laser) 1%

MCU PCB 1%

Controller PCB 1%

Table 87. Map 980: Horizontal Voids





Aux Tray.




Table 87. Map 980: Horizontal Voids (continued)













5. Check the Gear Drive Asm:a. Enter Service Mode (see “Accessing Service Mode”

on page 280.)b. Remove the Toner Cartridge.c. Run Diagnostic 1100 (see “Diagnostic Menu” on

page 284).d. Check the gear that meshes with the Toner

Cartridge.

Is the gear turning correctly?

Go to step 6 on page 275. Repair/replace the Gear DriveAsm.


Table 87. Map 980: Horizontal Voids (continued)



Do the horizontal voids occur regularly at intervalsaround 61mm (2.4 in)?



Go to step 7.


HVPS.3. Test for continuity between:v PJ26-11 and PJ261-11



Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv ROS Asm (Laser)v MCU PCBv Controller PCB


MAP 985: Vertical Band VoidsSymptom Explanation Suspected FRUs/Causes Probability

There are vertical bands on the printed page that areextremely light or missing entirely.

Toner Cartridge 50%

ROS Asm (Laser) 30%



MCU PCB 1%

Controller PCB 1%

Table 88. Map 985: Vertical Band Voids





Aux Tray.

Does the print still have vertical band voids?







Table 88. Map 985: Vertical Band Voids (continued)


3. Check the Bias Transfer Roll:a. Power off the printer.b. Remove the Bias Transfer Roll and inspect it for

damage and contamination.


Go to step 4. Replace the Bias Transfer Roll.

4. Check the ROS Asm:1. Power off the printer.2. Remove the ROS Asm (Laser).3. Inspect the laser window for contamination or

anything else that would block the laser path.4. Reinstall the ROS Asm.5. Print a Service Page from Tray 1 to the Main Output




230 v


v ROS Asm (Laser)v MCU PCBv Controller PCB



Chapter 2. Diagnostic Tools

Printer Power-On Sequence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Accessing Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Accessing Service Mode from the CE Laptop PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281Accessing Service Mode from the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Factory Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Factory Adjustment Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Test Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Test Print Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Printing the Service Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

Printing the Service Page from the CE Laptop PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

This chapter contains detailed procedures such as printing test pages, printing a configuration page, working withthe error log, and performing checks and test necessary to support diagnostics.


Printer Power-On Sequence CheckThe following sequence of events should occur when printer power is switched on (no network card installed, andno error codes):Table 89. Power-On Sequence

Time after power on Duration Event

0 seconds 5 seconds Motors activate

12 seconds Black rectangles display on the top line of the operatorpanel

Until powered off Fan activates

12 seconds Approximately 48 seconds INFOPRINT 21 INITIALIZING displays on operator panel

2 seconds All LEDs light on operator panel

55 seconds Approximately 10 seconds INITIALIZING PLEASE WAIT displays on operator panel

65 seconds 1 second ONLINE IN PROGRESS displays on operator panel

66 seconds Until other activity READY displays on operator panel

Note: If a network interface card (NIC) is installed, the timings will change and the printer might take up to fiveminutes to initialize.

Chapter 2. Diagnostic Tools 279

Service ModeService Mode allows you to run diagnostic routines, execute test prints, and change factory adjustments.

Accessing Service ModeThere are two ways to access the Service Mode for the Infoprint 21:v “Accessing Service Mode from the CE Laptop PC” on page 281v “Accessing Service Mode from the Operator Panel” on page 283


Accessing Service Mode from the CE Laptop PCTo enter Service Mode using a CE laptop PC attached to the Infoprint 21 serial Service Port perform the followingsteps:

Note: To set up a CE laptop PC to access service mode for the first time, click here:

Set up CE laptop PC

1. Power off the printer.2. Connect the CE laptop PC serial port to the Infoprint 21 serial Service Port using the serial cable contained in

kit P/N 62H4857.3. While pressing down both the Menu ↓ and Item ↓ keys, power on the printer.

Note: Continue holding down the keys until the message REQUEST RECEIVED is displayed on the operatorpanel.

4. The following messages display:INFOPRINT 21INITIALIZING

INFOPRINT 21REQUEST RECEIVED

DIAGNOSTIC MODEPLEASE WAIT

5. When initialization completes, the following message displays on the operator panel:DIAG MENUTEST = 1.0<0.0.

6. Power on the CE laptop PC.7. Start the Service PPP connection to the printer using a URL address of

http://10.0.0.2/ras/ras.htm


Note: The operator panel keys are disabled when the Service PPP connection is active.8. To exit Service Mode when using the CE laptop PC:

a. Close all applications on the CE laptop PCb. Power off the CE laptop PCc. Power off the printerd. Disconnect the cable from the CE laptop PC to the printere. Power on the printer


Accessing Service Mode from the Operator PanelTo enter Service Mode using the operator panel on the Infoprint 21 perform the following steps:1. Power off the printer.2. While pressing down both the Menu ↓ and Item ↓ keys, power on the printer.

Note: Continue holding down the keys until the message REQUEST RECEIVED is displayed on the operatorpanel.

3. The following messages display:INFOPRINT 21INITIALIZING

INFOPRINT 21REQUEST RECEIVED

DIAGNOSTIC MODEPLEASE WAIT

4. When initialization is complete, the following message displays on the operator panel:DIAG MENUTEST = 1.0<0.0.

5. Use the operator panel keys to navigate within the Service menus.6. To exit Service Mode when using the operator panel, power off and then power on the printer.


Service Mode FunctionsThe following functions are provided as menus in Service Mode when using either the CE laptop PC using theserial Service Port or the Infoprint 21 operator panel:v Diagnostic Menuv Factory Adjustment Menuv Test Print Menu

In addition, an Error Log Menu is provided in Service Mode for the CE laptop PC using the serial Service Port.

Diagnostic MenuThe Diagnostic Menu allows you to run diagnostic routines such as checking sensors/switches, running motorsand fans, and picking solenoids and clutches. The following sections describe how to run diagnostics using eithera CE laptop PC attached to Infoprint 21 serial Service Port or the Infoprint 21 operator panel.

Note: In this book, diagnostic numbers are specified as 1xxx; on the operator panel diagnostic numbers aredisplayed as 1.x.x.x.

Using the Diagnostic Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Diagnostic Menu link, which is displayed on the left side of the screen.3. The Diagnostic Menu screen is displayed. The right side of the Diagnostic Menu displays the options for

running diagnostic test:v Test Number: Enter the four digit diagnostic number, or use Test Name to select a test.v Test Name: Choose the diagnostic name from the pull-down list.v Test Count: Enter the number of repetitions of the diagnostic to be run.v Test Status: Displays the status of the diagnostic.v Test Results: Displays the output of the diagnostic.v Run Button: Select this button to start the diagnostic.v Stop Button: Select this button to stop running the diagnostic.


Using the Diagnostic Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283). The operator

panel displays the Diagnostic Menu:DIAG MENUTEST = 1.0<0.0.

2. To enter a test number, do the following.

Note: The “<” character indicates (points to) the current number position that can be changed.a. Press Value ↑ or Value ↓ to change the second number.b. Press Item ↑ or Item ↓ to move to the third number position.c. Press Value ↑ or Value ↓ to change the third number.

Note: For the Infoprint 21, the first number should always be a “1” and the last number shouldalways be a “0”.

3. Press Enter to run the diagnostic.


Diagnostic TestsThe following table list the diagnostic tests that are available for the Infoprint 21.Table 90. Diagnostic Test Routines

TestRoutine Component Comments

1010 Test Print Prints MCU test print -- controller not involved

1020 Sensor/Switch Test Displays OK after switch changes state

1030 Fuser Temperature Returns temperature in degrees Celsius (C).

1040 Fuser Set Temperature Returns temperature in degrees Celsius (C).

1050 ROM Check Sum

1100 Main Motor

1110 ROS Motor Speed depends on current resolution.

1120 Fan Motor High

1130 Exit Motor CW

1140 Exit Motor CCW Low

1150 Exit Motor CCW High

1160 Duplex Motor Low

1170 Duplex Motor High

1180 OCT Motor

1200 Tray 1 Pick Clutch



1250 Tray Feed Clutches

1260 Aux Tray Solenoid


Table 90. Diagnostic Test Routines (continued)

TestRoutine Component Comments

1270 Env Pick Clutch

1280 Registration Roll Clutch

1290 Offset

1300 Charge Roll AC

1310 Charge Roll DC

1320 Developer Bias AC

1330 Developer Bias DC

1340 Transfer Roll (-)

1350 Transfer Roll (+)

1360 Detack Saw

1370 Laser Diode Warning -- Can damage drum if left on.

1380 Option Direction Will only run once.

1390 Pressure Roller DC Bias


Factory Adjust MenuThe Factory Adjust Menu allows you to change factory settings in the printer. The following sections describe howto run diagnostics using either a CE laptop PC attached to the Infoprint 21 serial Service Port or the Infoprint 21operator panel.

Note: Do not change values in the Factory Adjust Menu (except for serial number or registration adjustments)unless IBM Technical Support instructs you to do so.

Using the Factory Adjust Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Factory Adjust Menu link, which is displayed on the left side of the screen.3. The Factory Adjust Menu screen displays. The right side of the Factory Adjust Menu displays a table showing

the adjustments that can be made to different parameters.4. To change an adjustment value, enter or select a new value and then select the Apply button on the menu.

You can use the Cancel button to clear any entered values.

Using the Factory Adjust Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.

DIAG MENUTEST = 1.0<0.0.

3. Press the Menu ↑ or Menu ↓ key until FACTORY ADJ MENU is displayed.4. Press the Item ↑ or Item ↓ key to scroll through the factory adjustments and their current values.

Note: The current value is indicated by an asterisk (*) following the value.5. Press the Value ↑ or Value ↓ key to change the current value.6. Press Enter to change the current value to the new displayed value. An asterisk (*) appears next to the value

to indicate that it is now the current value.


Factory Adjustment ParametersThe following table describes the factory adjustment parameters that can be changed.Table 91. Factory Adjustment Parameters

Adjustment Name Operator Panel Text Possible Values

Serial Number S/N 00-00000 *Note: Values entered using the operator panel aresimilar to Diagnostic tests with the arrow indicatingthe position to enter data.

00-00000 to 99-99999

Resolution Adjustment RES ADJ= * 600, 1200

Laser Diode Power Adjustment LASER= 8 * 0-15

Fuser Standby Temp FUSERSTBY= 8 * 0-8

Fuser Running Temp FUSERRUN= 8 * 0-15

Fuser Cleaning Temp FUSERCLEAN= 7 * 0-15

Registration Adj, Lead Edge, Tray 1 REG LEAD 1= 8 * 0-15

Registration Adj, Side to Side, Tray 1 REG SIDE 1= 4 * 0-15





Registration Adj, Lead Edge, MBF REG LEAD M= 8 * 0-15

Registration Adj, Side to Side, MBF REG SIDE M= 4 * 0-15

Paper Size Adj, MBF PPR SIZE M= * Paper types/sizes

Registration Adj, Lead Edge, Envel REG LEAD E= 8 * 0-15

Registration Adj, Side to Side, Envel REG SIDE E= 4 * 0-15

Paper Size Adj, Envel PPR SIZE E= * Paper types/sizes


Test Print MenuThe Test Print Menu allows you to print various types test print patterns using any of the possible input trays,output bins, and processing options (such as offsetting) that are available on the printer. The following sectionsdescribe how to print test prints using either a CE laptop PC attached to the Infoprint 21 serial Service Port or theInfoprint 21 operator panel.

Using the Test Print Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Test Print Menu link, which is displayed on the left side of the screen.3. The Test Print Menu screen displays. The right side of the Test Print Menu displays the options that can be

selected for printing test prints. To change any option, enter or select a new value.4. Select the Run button on the menu to print the test print with the selected options.

Note: The Stop button will cancel the test print that is in progress.

Using the Test Print Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.


3. Press the Menu ↑ or Menu ↓ keys until TEST PRINT MENU is displayed.4. Press the Item ↑ or Item ↓ key to scroll through the test print options and their current values.

Note: The current value is indicated by an asterisk ″*″ following the value. See Table 92 on page 292 for adescription of the test print options.

5. Press the Value ↑ or Value ↓ keys to change the current value of a test print option.6. Press Enter to change the current value to the new displayed value.

Note: An asterisk (*) will appear next to the displayed value to indicate that it is now the current value.7. Select the RUN TEST PRINT item from the TEST PRINT MENU and press the Enter key to print the selected

test print and options.


Test Print OptionsThe following table shows the test print options and values that are available on the Infoprint 21.Table 92. Test Print Options

Laptop Text withDefaults

Operator Panel Textwith Defaults

Possible Values Note

Print Type: SERVICE TYPE= SERVICE * SERVICE, ERROR LOG,WHITE, BLACK, GRID,PRINT QUALITY

v SERVICE: Similar to the Printer Configurationpage except NIC information is not shown.

v ERROR LOG: An error log containing the last 25errors with print count.

v WHITE: An all white page used for diagnosingprint quality problems

v BLACK: An all black page used for diagnosingprint quality problems

v GRID: A grid pattern across the entire page usedfor diagnosing print quality problems

v PRINT QUALITY: A sample print with patternsused for diagnosing print quality problems

Number of prints: 001 PRINTS=1 * 001 - 999 Enter up to three digits to specific the number oftest prints to print. TYPE=BLACK will only print 1black print.

Paper Source: Tray 1 SOURCE= TRAY 1 * TRAY 1, TRAY 2, TRAY3, AUX TRAY,ENVELOPE

TRAY 2, TRAY 3, and ENVELOPE are displayedonly if they are installed.

Paper Output: Main OUTPUT= MAIN * MAIN, OFFSET OFFSET is displayed only when the Offset OutputBin is installed.

Duplex: Off DUPLEX= OFF * OFF, ON This menu item is displayed only when the duplexunit is installed.

Offset: Off OFFSET= OFF * OFF, ON This menu item is displayed only when the OffsetOutput Bin is installed.


Table 92. Test Print Options (continued)

Laptop Text withDefaults

Operator Panel Textwith Defaults

Possible Values Note

Offset Count: 01 OFFSET_CNT= 1 * 01 - 99 This menu item is displayed only if the OffsetOutput Bin is installed. Use up to two digits to enterthe value.

RUN TEST PRINT This menu item is only available from the operatorpanel. Select this item and press Enter to print theselect test print and options.


Error LogThe Infoprint 21 error log can be displayed on the CE laptop PC attached to the printer’s serial Service Port,however the error log cannot be displayed on the operator panel. To display the error log on the CE laptop,access Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281) and select the ErrorLog link, which is displayed on the left side of the screen.

The error log can also be printed using the CE laptop PC attached to the Infoprint 21 serial Service Port or theoperator panel by selecting the Error Log item in the Test Print Menu (see “Using the Test Print Menu from theOperator Panel” on page 291). This printout will show the 25 most recent errors along with the page count atwhich the error occurred and a text description of the error. The errors are ordered with most recent error beingindex #1 and oldest error being index #25.

An abbreviated error log showing the 10 most recent errors is also printed on the Printer Configuration page andon Service Test Print item that can be selected in Service Mode from the Test Print Menu (see “Printing theService Page” on page 295).


Printing the Service PageThe following sections describe how to print the Service Page using a CE laptop PC attached to the Infoprint 21serial Service Port or by using the Infoprint 21 operator panel.

Printing the Service Page from the CE Laptop PC1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Test Print Menu link, which is displayed on the left side of the screen.3. The Test Print Menu screen displays. The right side of the Test Print Menu will display the options that can be

selected for printing test prints. Select Service for the print type item.4. Select and change any other items that you want to change from the default values.5. Select the Run button on the menu to print the test print with the selected options.

Note: The Stop button will cancel the test print that is in progress.


Printing the Service Page from the Operator Panel1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.


3. Press the Menu ↑ or Menu ↓ key until TEST PRINT MENU is displayed.4. Press the Item ↑ or Item ↓ keys until the TYPE item is displayed.5. If TYPE=SERVICE* is not displayed:

a. Press the Value ↑ or Value ↓ key until TYPE=SERVICE is displayed.b. Press Enter .

6. If you want to change other items to new values, do the following:a. Press the Item ↑ or Item ↓ keys to select the item.b. Press the Value ↑ or Value ↓ key to select the new value.c. Press Enter . An asterisk (*) will appear next to the displayed value to indicate that it is now the current

value.7. Select the RUN TEST PRINT item from the TEST PRINT MENU and press the Enter key to print the Service

Test print.

Note: If the test print does not print, press the Online key to display the error message.


Chapter 3. Wiring and Pin-Out Diagrams

Master Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299

Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . 299Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and to Fan Asm and Front Cover

Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and Fuser Asm . . . . . . . . . . . . . . 301Pin-Out Diagram D: MCU PCB to Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear Cover Interlock Switch . . . . . . . . . 303Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to Paper Low Photo Sensor and Lift

Control Photo Sensor, Pick Clutch, Feed Clutch, and Tray Lift Motor . . . . . . . . . . . . . . . . . . . . 304Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor, and Main Motor . . . . . . . . . 305Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor, Aux Pick-up Solenoid,

Registration Sensor, Registration Clutch, Toner Sensor, and Envelope PCB. . . . . . . . . . . . . . . . . 306Pin-Out Diagram J: MCU PCB to Laser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307


Master Wiring DiagramPin-Out Diagram A: Pin-Out Diagram B: Pin-Out Diagram C: Pin-Out Diagram D: Pin-Out Diagram E:Pin-Out Diagram F: Pin-Out Diagram G: Pin-Out Diagram H: Pin-Out Diagram J:

HA

K31

4

MCU PCB

Paper SizePCB

(Tray 1)

Offset FullStack Sensor

Offset ExitSensor

Offset PCB

Offset MechanismMotor

EnvelopeExit

Sensor

EnvelopeNo-PaperSensor

EnvelopeClutch

Envelope PCB

Offset DriveMotor

DuplexFace-UpSensor

Duplex Motor

Duplex PaperSensor

Duplex PCB

Offset DirectionSolenoid

Offset DirectionHome Sensor

No-Paper SensorFeed PCB

InterfacePCB

AUXNo-PaperSensor

Feed ClutchTray LiftMotorPick Clutch

HVPS

CR

DB

TR

DST

Fuser Asm

BTRAsm

TonerCartridge

ExitSensor

Heater Lamp

PRB

LaserAsm

Lift ControlSensor

Low PaperSensor

AUX PickSolenoid

MM

MM

RegistrationSensor

RegistrationClutch

Front CoverInterlockSwitch

Fan Motor

AC

5 V DCPCB

ControllerPCB

OperatorPanel

LVPS

P351

P341

P/J61

P/J66

P/J451

P/J45

P/J43

P/J432

P/J433

P/J41

P/J661 P/J662 P/J651 P/J641P/J672P/J673

P/J65 P/J64 P/J67

P531J541

P/J209

P/J39

P/J360

P/J37

P/J38

P/J412

P/J415 P/J416

P/J414

P/J288

P/J413

P/J361

P/J35

P/J22

P/J25

P/J26

P/J27

P/J9P

6J

36

P/J282

P/J11

P/J281

P/J283

P/J284

P/J285

P/J1

P/J101

P/J28

P/J4

P/J261

P/J271

P/J262

P/J223

P/J213

P/J211

P/J212

P/J21

P/J33

P/J331

P/J51

P/J34

P/J418

P/J411

J202

P/J225

P/J226

P/J227

P/J417

P/J228

P/J224

P/J223 P/J210

J391

P/J231

P/J23

TonerSensor

P/J421

P/J42

Toner CartridgeKey Sensor

P/J251

Full StackPhotoSensor

Rear CoverInterlockSwitch

P/J31

P/J30

P/J311

Feed PCB Feed PCB

Option PaperSize PCB(Tray 3)

Option PaperSize PCB(Tray 2)

Paper SizeSensor

Paper SizeSensor

Paper SizeSensor

P/J53

P/J54

P/J61 P/J61

P/J53

P/J52

M

ExitMotor

MainMotor

M P/J32

P/J29

P/J44

P511J521

F

J

H

E

E

G

G

G

C

C

C

D

A

B

B

B

B

B

A

H

F

Alphabetical Character on Wire Represents Pin-Out Diagrams

Chapter 3. Wiring and Pin-Out Diagrams 298

Pin-Out DiagramsThe pin-out diagrams illustrate the electrical relationships between printer components. Each pin-out wire has asignal name, and is terminated at both ends with a connector-pin number. The connector number is listed at thetop of the connector. The Master Wiring Diagram shows electrical connections within the printer.

Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm

LVPS PBCMCU PBC

Fuser Asm

FAN ON/HEAT

/FHIGH3.3V

FAN ALARMGND5V

24V RTN24V RTN24V RTN

24V24V24V

AC HOTAC NUT

1413121110

987654321

1413121110987654321

12

P/J281

P/J11 P/J271

P/J28

HK

E00

1FA


Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and toFan Asm and Front Cover Interlock SwitchMaster Wiring Diagram

5 V DC PCBController PCB

LVPS

24V24V

RTN24V

GND3.3V

GND5V

24VFAN ALRM

RTN

123

12

21

43

21

21

P/J283

P/J284

Fan Asm

Front CoverInterlockSwitch

P/J1

P/J282

P/J288P/J19

P101

HK

E00

2FA


Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and FuserAsmMaster Wiring Diagram

HVPSMCU PCB

CR-DRCR-ACCR-CHDB-DATR(-)TR(+)

DB. DCDTS

TR-A/DTR-D/AGND3.3VRTN24VPRB

CRDB

Toner Cartridge

Drum

FG

BCR

Mag Roll

BTR Asm

BTRTR

DTS

Fuser Asm

PRB

123456789

101112131415

151413121110987654321

P/J261

P/J271

P/J26

HK

E00

3FA


Pin-Out Diagram D: MCU PCB to Fuser AsmMaster Wiring Diagram

543

MCU PCB Fuser Asm

/EXITGND3.3V

/EXIT(IN)GND3.3V

STS(A/D)GND

STS(A/D)GND

543

21

123

123

12

45

21

P/J27

Exit Sensor

STS

P/J275

P/J274

HK

E00

4FA

P/J271


Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear CoverInterlock SwitchMaster Wiring Diagram

MCU PCB

/FSTKGND3.3V

24V EXIT MOT24V

123

321

21

P/J311

Full StackPhoto Sensor

Rear CoverInterlock Switch

P/J31

P/J30

HK

E00

5FA


Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to PaperLow Photo Sensor and Lift Control Photo Sensor, Pick Clutch, FeedClutch, and Tray Lift MotorMaster Wiring Diagram

3.3VGND

LOW PAP1/TG MCUFD TXDFD RXD/FEED3/FEED2

/NO PAP3/NO PAP2

/LOW PAP3/LOW PAP2

3.3VGND24V

24V RTNReserved

/Feed1/NO PAP1/LOW PP1

3.3VGND

NUD LOW

FEED1 ON

/TRNC(OUT)24V I/L

24V I/L

24V

NUD MOTOR

24V I/L

321

321

4321

7654321

7654321

1234

12

12345

123

1234567891011121314151617

1716151413121110

987654321

456

P/J661

P/J662

P/J651

P/J672P/J673

P/J65

P/J64

P/J67

Paper LowPhoto Sensor

No-PaperPhoto Sensor

MCU PCB

Paper Size Sensors

Paper Size PCB

Feed PCB

Option Paper Drawer

P/J51

Lift ControlPhoto Sensor

PickClutch

FeedClutch

Tray Lift Motor

P/J66P/J331 P/J33

P/J61

HK

E00

6FA


Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor,and Main MotorMaster Wiring Diagram

5V5V LD/CRUGND

/EXIT XB/EXIT XA/EXIT B/EXIT A

24V EXIT MOT

/M RSV/MARM

/MMOT ON24V RTN24V RTN24V RTN

24V24V24V

4321

1234

54321

987654321

P/J25 P/J251

P/J32

P/J29

Toner Cartridge Key Sensor

Exit Motor

Main Motor

MCU PCB

HK

E00

7FA


Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor,Aux Pick-up Solenoid, Registration Sensor, Registration Clutch, TonerSensor, and Envelope PCBMaster Wiring Diagram

/NO PRM3.3V NOPRM

/SOLM/REG

3.3V REG/REG CL/TONER

GND24V

24V RTN/EPRS

/NOPRE3.3V

SOLE

/NO PRMGND3.3V

/SOLM24V

/REGGND3.3V

/REG CL

24V

/TONER24V

RTN/EPRS/NOPRGND3.3V

SOLE(OUT)24V

24V RTN

16151413121110987654321

123456789

10111213141516

321

4321

7654321

543

2

1

123

1234

1234

21

123

P/J23 P/J231P/J45

P/J44

P/J43

P/J421

P/J418

P/J42

P41

P/J432

P/J433

P/J451

Aux No-Paper Sensor

Aux Pick-Up Solnoid

Registration Sensor

Registration Clutch

Toner Sensor

Envelope Connector

Envelope PCB

MCU PCB Interface PCB

HK

E00

8FA


Pin-Out Diagram J: MCU PCB to Laser AsmMaster Wiring Diagram

P.DATA/nP.DATA

Differential

/LD/LDEN

Vmf(D/A)GND5VLD

SG/SOS(IN)

5V

24V24V RTN

/RMOT(OUT)

/RCLK(OUT)

12

123456

789

101112

13

21

654321

321

54321

P/J22

P/J21

P/J223

P/J213

P/J211

P/J212

Laser AsmMCU PCB

HK

E00

9FA


Chapter 4. Locations

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Major Assemblies, Components, and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312PCBs (Printed Circuit Boards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315


Controller

Item Ref

HA

K31

6

9

1

8

7

6

5

4

3

2Controller PCB 1

Code Compact Flash Slot 2

Memory DIMM Slots 3

IPDS Compact Flash Slot 4

NIC (Network InterfaceCard)

5

Hard Drive Connector 6

Service (Serial) Port 7

Font Compact Flash Slot 8

Parallel Port 9

Chapter 4. Locations 309

Covers

Item Ref

5

1

2

3

4

HA

K30

9

6

7

8

Exit Cover 1

Top Cover 2

Front Cover Asm 3

Right Cover 4

Front Left Cover 5

Controller Cover 6

Left Cover 7

Rear Cover Asm (WithFace-Up Bin), Rear CoverAsm (Without Face-UpBin)

8


Major Assemblies, Components, and Supplies

Item Ref

5

1

2

7

6

3

4

HA

K31

8

Fan Motor 1

Toner Cartridge 2

ROS Asm (Laser) 3

Main Motor 4

Gear Drive Asm 5

Bias Transfer Roll 6

Fuser Asm 120 v, FuserAsm 230 v

7


Optional Features

Item Ref

HA

K30

6

4

5

1

3

2

Offset Asm 1

Env Tray Asm 2

Option Paper Drawers 3

Duplex Asm 4

Rear Cover Asm (WithFace-Up Bin), Rear CoverAsm (Without Face-UpBin)

5


PCBs (Printed Circuit Boards)

Item Ref

5

6

7

8

9

1

2

3

4

HA

K31

9

Controller PCB 1

MCU PCB 2

5 V DC PCB 3

Main Motor 4

Interface PCB 5

HVPS 6

Feed PCB 7

Paper Size PCB 8

LVPS 120V, LVPS 230V 9


RollersItem Ref

7

5

4

6

8

3

2

3

2

3

2

19 18

17

16

1311

12

11

10

11

9

14

151

1

1

HA

K31

2

Pick Roll Asm 1

Tray Retard Roll 2

Feed Roll Asm 3

Aux Pick Roll 4

Rubber Registration Roll 5

Metal Registration Roll 6

Toner Cartridge 7

Bias Transfer Roll 8

Fuser Asm 120 v, FuserAsm 230 v

9

Exit Roll 1 10

Exit Pinch Roll 11

Exit Roll 2 12

Exit Roll 3 13

Duplex Roll 14

Duplex Drive Belt 15

Offset Roll 16

Offset Pinch Roll 17

Offset Exit Roll 18

Offset Exit Pinch Roll 19


Sensors and SwitchesItem Ref

7

5

4

6

8

3

2

13

14

14

14

15

15

15

12

1110

9

1

1

1 HA

K31

3

Lift Control Photo Sensor 1

Paper Size Sensor Asm 2

Aux No-Paper PhotoSensor

3

Registration Sensor 4

Fuser Exit Sensor 5

Full Stack Photo Sensor 6

Offset Exit Photo Sensor 7

Offset Full Stack PhotoSensor

8

Duplex Paper PhotoSensor

9

Front Cover InterlockSwitch

10

Rear Cover InterlockSwitch

11

Duplex Face-up PhotoSensor

12

Toner Cartridge KeySensor

13

No-Paper Photo Sensor(Feed PCB)

14

Paper Low Photo Sensor 15


Chapter 5. Removals and Replacements

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Text and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3255v DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Aux Drive Gear Shaft and Aux Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Aux No Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Aux No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Aux Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Aux Pick Up Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Aux Pick Up Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Aux Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Aux Retard Pad Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Aux Tray Bottom Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Bearing and Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Duplex Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Duplex Connector Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Duplex Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353


Duplex Face Up Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Duplex Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Duplex Motor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Duplex Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357Duplex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Duplex Roll Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359Duplex Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Duplex Upper Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361ENV Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362ENV Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363ENV Clutch (Electric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364ENV Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366ENV Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367ENV Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368ENV Large Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369ENV No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370ENV No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371ENV Retard Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372ENV Roll Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373ENV Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375ENV Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376ENV Tray Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377ENV Tray Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384Face-Up Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386

Chapter 5. Removals and Replacements 317

Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389Feed Tray Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392Front Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398Fuser Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Harness (J27, J11, J262 - J271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401Harness (J34-P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Left Handle Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410Lift Control Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415Metal Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Middle Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420


Offset Direction Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422Offset Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423Offset Exit Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424Offset Exit Bin Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Offset Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428Offset Inner Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Offset Inner Chute Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Offset Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Offset Mechanism Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Offset PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Offset Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435Offset Tray Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437Option Chute Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440Option Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441Option Gear Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Option Harness (J52-J521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443Option Harness (J53-531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446Option Lift Control Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447Option No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449Option Paper Low Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450Option Paper Size Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452


Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Option Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459Option Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460Option Top Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463Paper Size Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464Paper Size Housing Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Paper Sizing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466PCB Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Rear Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476Rear Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485Rubber Registration Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Rubber Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490


Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Tray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494Tray Lift Motor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498Tray Retard Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502


General Information

Text and IllustrationsNumeric callouts in text are enclosed in parentheses. Unless otherwise noted, all text callouts refer to theillustration to the left of that text.

Printer orientation is defined as follows.


Preparation1. Power off and unplug the printer.2. Remove the 550-Sheet Tray Asm.3. Open the Front Cover.4. Remove the Toner Cartridge and store it in a dark, safe place that is free from direct sunlight.5. When working near the Fuser Asm, wait until the Fuser Asm is cool.

CAUTION:

<2-43> High temperature; switch off the printer and allow at least 30 minutesfor parts in this area to cool before handling.

hcsf

0243

6. Disconnect all interface cables from the rear panel of printer.7. To eliminate static electricity, wear wristbands or another grounding device. See “Electrostatic Discharge (ESD)

Procedures” on page 26.


Removal and Replacement Procedures


550-Sheet Tray AsmParts Reference: 550-Sheet Tray Asm

Removal :1. Slide the 550-Sheet Tray Asm (1) from the printer.

Replacement: Reverse the removal procedure.


5v DC PCBParts Reference: 5 V DC PCB

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect P/J288 from the 5V DC PCB (1).5. Disconnect P/J101 from the 5V DC PCB.6. Remove the two screws (2) that hold the 5V DC

PCB to the printer.7. Remove the 5V DC PCB.



Aux Drive Gear Shaft and Aux Drive GearParts Reference: Aux Drive Gear Shaft and Aux DriveGear

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Hold the Aux Drive Gear (1) and remove the Aux

Drive Gear Shaft (2).6. Remove the Aux Drive Gear.



Aux No Paper Actuator

1

32

HK

A01

2FD

Parts Reference: Aux No Paper Actuator

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release two hooks (2) and open the Aux Tray

Bottom Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).

Continued on p. 329.


Parts Reference: Aux No Paper Actuator

Continued from p. 328.10. Remove the Aux No Paper Actuator (2) from the

back of the Aux Tray Bottom (1).



Aux No Paper Photo Sensor

1

32

HK

A01

2FD

Parts Reference: Aux No Paper Photo Sensor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hooks and open the Aux Tray Bottom

Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).

10. Remove the Aux Tray Bottom Spring (3) from theAux Tray Asm.



Parts Reference: Aux No Paper Photo Sensor

Continued from p. 330.11. Disconnect P/J451 (4) from the Aux No Paper

Photo Sensor (5).12. Release the hooks of the Aux No Paper Photo

Sensor, and remove the Aux No Paper Sensor fromthe Aux Tray Asm.



Aux Pick Roll

1 2

HK

A00

9FB

Parts Reference: Aux Pick Roll

Removal :1. Open the Front Cover Asm (p. 391).2. Unhook the latch on the right Aux Pick Roll Core (2)

and move it to the right.3. Move the Aux Pick Roll (1) to the right, then raise it

upward to remove from the Aux Tray Asm.



Aux Pick Roll Asm

1

HK

A0Y

3FB

2

3


Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Unhook the Aux Pick Roll Right Cam (1) and move it

to the left.8. Unhook the Aux Pick Roll Left Cam (2) and move it

to the right.




Continued from p. 333.9. Align the pin on the Aux Pick Roll Asm (3) with the

left slit of the Aux Tray Asm. Then slide the AuxPick Roll Asm to the left and remove the right shaftof the Aux Pick Roll Asm from the Aux Tray Asm.

10. Lift the right shaft of the Aux Pick Roll Asm andslide the Aux Pick Roll Asm to the right to remove itfrom the Aux Tray Asm.



Aux Pick Up GearParts Reference: Aux Pick Up Gear

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Unhook and remove the Aux Pick Up Gear (1) from

the Aux Pick Roll Shaft.



Aux Pick Up Gear SpringParts Reference: Aux Pick Up Gear Spring

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Unhook the Aux Pick Up Gear Spring (1) from the

Aux Pick Up Gear (2) and from the hole in the AuxTray Asm.



Aux Pick Up Pad AsmParts Reference: Aux Pick Up Pad Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release two hooks and open the Aux Tray Bottom

Asm (1).9. Rotate the Aux Pick Up Pad Asm (3) by 90 degrees

to the front and remove the Aux Pick Up Pad Asm.



Aux Pick Up SolenoidParts Reference: Aux Pick Up Solenoid

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the one screw (1), and then remove the Aux

Pick Up Solenoid (2) from the Aux Tray Asm.



Aux Retard Pad Asm

1

32

HK

A01

2FD

Parts Reference: Aux Retard Pad Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hooks and open the Aux Tray Bottom

Asm (1).



Parts Reference: Aux Retard Pad Asm

Continued from p. 339.9. Remove the Aux Pick Up Pad Asm (p. 337).

10. Release the left and right brackets of the AuxRetard Pad Asm (3) from the Aux Tray Asm. (2)and remove the Aux Retard Pad Asm.



Aux TrayParts Reference: Aux Tray

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the E-clip (3) that holds the Aux Tray Stop

to the Aux Tray (1).3. Insert a small screwdriver between the Aux Tray and

the Front Cover Asm as shown, and remove the AuxTray right peg from the Front Cover Asm.

4. Use the small screwdriver to release the Aux Trayleft peg from the Front Cover Asm.

5. Align the peg of the Aux Tray Stop (2) with the slit inthe Aux Tray, and then remove the Aux Tray from theFront Cover Asm.



Aux Tray AsmParts Reference: Aux Tray Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Disconnect the following three connectors (1) from

the Interface PCB:v P/J41v P/J44v P/J45

5. Release the two clamps (not shown) that hold theharnesses of the Aux Tray Asm (2) to the printer.

6. Remove the four screws (3) that hold the Aux TrayAsm to the printer.

7. Remove the Aux Tray Asm.



Aux Tray Bottom Asm

13

2

HK

A01

2FE

Parts Reference: Aux Tray Bottom Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hook (2) and open the Aux Tray Bottom

Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).



Parts Reference: Aux Tray Bottom Asm

Continued from p. 343.10. Use a screwdriver to unhook the right bearing (2).11. Use a screwdriver to unhook the left bearing (4).12. Remove the Aux Tray Bottom Asm (1) from the Aux

Tray Asm (3).13. Remove the bearings from the left and right shafts

of the Aux Tray Bottom Asm.



Bearing and Exit Roll 23

23

1

HK

A04

0FB

Right

Left

Parts Reference: Exit Roll 2

Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the Rear Cover Interlock Switch (p. 475).3. Lift the tab on Exit Gear-17 (1) and slide Exit

Gear-17 from the Exit Roll 2 (2).4. Use a small screwdriver to remove the left and right

bearings (3) from the Exit Asm.5. Remove the Exit Roll 2 from the Exit Asm.

Note: When the Exit Roll 2 is removed, the two ExitPinch Rolls fall out.

6. Remove the left and right Bearings from Exit Roll 2.



Bias Transfer RollParts Reference: Bias Transfer Roll

Notes:1. In the following procedures, do not touch the surface

of the Bias Transfer Roll or the Detack Saw of theBTR Support Asm.

! CAUTION:

<2-24> Sharp edges exist in this area. hcsf

0224

2. When removing the Bias Transfer Roll from theprinter, take care not to damage the roll.

3. After removing the Bias Transfer Roll, roll it in paperand store it in a safe place.

4. When replacing the Bias Transfer Roll with a newone, peel off the paper that protects the roll of thenew Bias Transfer Roll before mounting.

Removal :1. Open the Front Cover Asm.2. Remove the Toner Cartridge.3. Push to unlock the left and right latches of the BTR

Asm (1) that hold the Bias Transfer Roll to theprinter.

4. Hold the left and right knobs of the Bias TransferRoll and remove the Bias Transfer Roll from the BTRAsm.



BTR Support Asm

2

1

4

4

3

HK

A03

4FC

Parts Reference: BTR Support Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the one screw (1) that attaches the DTS

Wire to the BTR Support Asm (2).10. Remove the one screw (3) that attaches the TR

Wire to the BTR Support Asm.11. Remove the two screws (4) that hold the BTR

Support Asm to the printer.12. Remove the BTR Support Asm.



Controller CoverParts Reference: Controller Cover

Removal :1. Loosen the two thumbscrews (1) that hold the

Controller Cover (2) to the printer.2. Remove the Controller Cover.



Controller PCB

3

3 HK

A0Y

6FB

2

2

2

RightLeft

1

Parts Reference: Controller PCB

Removal :1. Remove the Controller Cover (p. 348).2. Disconnect P/J9 from the Controller PCB (1).3. Disconnect P/J4 from the Controller PCB.4. Remove the five screws (2) that hold the Controller

PCB to the printer.5. Remove the five screws (3) that hold the rear bezel

to the printer.6. Move the Controller PCB to the rear and disconnect

the connector P/J6 from the printer.7. Remove the Controller PCB.

Note: The Controller PCB replacement part may notcome with a mounting bezel. If it does not include amounting bezel, remove the bezel from the originalpart and install it on the replacement part.



Duplex Asm

HK

A0D

0FC

1

Right

Left

Parts Reference: Duplex Asm

Removal :1. Open the Rear Cover.2. Push in the left and right levers (1) of the Duplex

Asm and remove the Duplex Asm from the printer.



Duplex Bottom Cover

1

HK

A0F

0FB

Bottom

Top

Parts Reference: Duplex Bottom Cover

Removal :1. Remove the Duplex Asm (p. 350).2. Release the hooks that hold the Duplex Bottom

Cover (1) to the Duplex Asm.3. Remove the Duplex Bottom Cover from the Duplex

Asm.



Duplex Connector AsmParts Reference: Duplex Connector Asm

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Disconnect connector P/J39 (1) from the Duplex

PCB.5. Release the harness of the Duplex Connector Asm

from the three hooks of the Duplex Asm.6. Remove the two screws (2) that hold the Duplex

Connector Asm (3) to the Duplex Asm.7. Slide the harness of the Duplex Connector Asm from

the hole in the Duplex Asm.8. Remove the Duplex Connector Asm.



Duplex Drive BeltParts Reference: Duplex Drive Belt

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the Duplex Roll Retaining Clip (p. 359).8. Remove the Duplex Drive Belt (1) from the gears of

the Duplex Asm.



Duplex Face Up Photo SensorParts Reference: Duplex Face-up Photo Sensor

Removal :1. Remove the Duplex Asm (p. 350).2. Release the hooks and remove the Duplex Face Up

Photo Sensor (1) from the Duplex Asm.3. Disconnect connector P/J361 (2) from the Duplex

Face Up Photo Sensor.



Duplex MotorParts Reference: Duplex Motor

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Disconnect connector P/J38 (1) from the Duplex

PCB.5. Release the Duplex Motor harness from the two

hooks of the Duplex Asm.6. Remove the two screws (3) and remove the Duplex

Motor (2) from the Duplex Asm.



Duplex Motor CoverParts Reference: Duplex Motor Cover

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the two screws (1) and remove the Duplex

Motor Cover (2) from the Duplex Asm.



Duplex Paper Photo Sensor

2

1

HK

A0F

1FB

Bottom

Top

Parts Reference: Duplex Paper Photo Sensor

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Disconnect connector P/J37 (1) from the Duplex

PCB.4. Release the hooks that hold the Duplex Paper Photo

Sensor (2) to the Duplex Asm and remove theDuplex Paper Photo Sensor.



Duplex PCBParts Reference: Duplex PCB

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Release the hook that holds the Duplex PCB (1) to

the Duplex Asm and remove the Duplex PCB.4. Disconnect the following connectors from the Duplex

PCB.v P/J36v P/J37v P/J38v P/J39



Duplex Roll Retaining ClipParts Reference: Duplex Roll Retaining ClipNote: This procedure describes how to remove all threeDuplex Roll Retaining Clips. Only remove the ones youneed to remove.

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Release the hook on the rear Duplex Roll Retaining

Clip (1) and remove the Duplex Roll Retaining Clip.7. Release the hook on the middle Duplex Roll

Retaining Clip (2) and remove the Duplex RollRetaining Clip.

8. Release the hook on the front Duplex Roll RetainingClip (3) and remove the Duplex Roll Retaining Clip.



Duplex Top CoverParts Reference: Duplex Top Cover

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Press the two levers and open the Duplex Top Cover

(1).6. Release the right shaft of the Duplex Top Cover from

the bearing, and slide the Duplex Top Cover to theupper right from the Duplex Asm.



Duplex Upper GuideParts Reference: Duplex Upper Guide

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the two screws (1) and remove the Duplex

Upper Guide (2) from the Duplex Asm.



ENV Arm WeightParts Reference: Env Arm Weight

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the right side of ENV Arm Weight (1) from

the right shaft of the ENV Tray Asm (3).3. Remove the ENV Arm Weight and ENV Lower Arm

Weight (2) from the ENV Tray Asm.4. Remove the right side of ENV Arm Weight and from

the right shaft of ENV Weight Cover.5. Pull the right side of ENV Weight Cover to the front

and right, then remove the ENV Lower Arm Weight.



ENV Bottom CoverParts Reference: Env Bottom Cover

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the two screws (1) and then remove the

ENV Bottom Cover (2) from the ENV Tray Asm.3. Remove the ENV Connector and Harness

(J411-J418) from the ENV Bottom Cover.



ENV Clutch (Electric)Parts Reference: Env Clutch - Electric

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375).4. Remove the ENV PCB.5. Remove the ENV Gear Cover (p. 368).6. Slide the ENV Clutch (Torque) (1) off of the shaft of

ENV Roll Shaft.



Parts Reference: Env Clutch - Electric

Continued from p. 364.7. Slide the Bearing (2) off of the shaft Clutch ELEC17

(3).8. Slide the ENV Clutch (Electric) (4) and Harness

(J413-J416) (5) off of the shaft of ENV Shaft Clutch(Electric).

9. Disconnect connector P/J416 (6) from the ENVClutch (Electric).



ENV Connector - Female

HK

A06

8FD

4

1

2

3

Parts Reference: Env Connector - Female

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Slide the ENV Connector Plate (1) to the left and

remove it from the Aux Tray Asm (2).5. Remove the two screws (3) that hold the ENV

Connector (4) to the ENV Connector Plate. Thenremove the ENV connector.



ENV Exit Photo SensorParts Reference: Env Exit Photo Sensor

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Release the two hooks that hold the ENV Exit Photo

Sensor (1) to the ENV Top Cover, and remove theENV Exit Photo Sensor.

5. Disconnect connector P/J417 (2) from the ENV ExitPhoto Sensor.



ENV Gear CoverParts Reference: ENV Gear Cover

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Remove the ENV PCB. Parts like the gear and clutch will

easily drop when the cover is removed. Take care not tolose them.

5. Remove two screws (1) and remove the ENV Gear Cover(2) from the ENV Tray Asm.

6. Unhook the following harnesses from the ENV Gear Cover:v Harness (J413-J416) connected to the ENV Clutch

(Electric)v Harness (J414-J415) connected to the ENV No Paper

Photo Sensor7. Slide the following harnesses through the hole in the ENV

Gear Cover:v Harness (J411-J418) connected to the ENV Connectorv Harness (J413-J416) connected to the ENV Clutch

(Electric)v Harness (J414-J415) connected to the ENV No Paper

Photo Sensor



ENV Large Pinch RollParts Reference: Env Large Pinch Roll

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Remove the ENV Retard Roll Asm (p. 372).5. Remove the ENV Large Pinch Roll (1) from the ENV

Top Cover.6. Remove the bearings (2) from the shaft of ENV

Large Pinch Roll.7. Remove the rollers (3) from the shaft of ENV Large

Pinch Roll.



ENV No Paper ActuatorParts Reference: Env No-Paper Actuator

Removal :1. Remove the ENV Tray Asm (p. 376)2. Remove the ENV Bottom Cover (p. 363)3. Release the shaft of the ENV No Paper Actuator (1)

from the the ENV Tray Asm, and remove the ENVNo Paper Actuator.



ENV No Paper Photo SensorParts Reference: Env No Paper Photo Sensor

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV No Paper Actuator (p. 370)4. Release the hooks and remove the ENV No Paper

Photo Sensor (1) from the ENV Tray Asm.5. Disconnect connector P/J415 (2) from the ENV No

Paper Photo Sensor.



ENV Retard Roll Asm

1

2

HK

A0N

1FB

Bottom

Top

Parts Reference: Env Retard Roll Asm

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375). Be careful not

to lose the ENV Retard Spring (2).4. Remove the shaft of ENV Retard Roll Asm (1) from

the bearing of the ENV Top Cover, and remove theENV Retard Roll Asm.



ENV Roll ShaftParts Reference: ENV Roll Shaft

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375).4. Remove the ENV PCB.5. Remove the ENV Gear Cover (p. 368).6. Slide the ENV Clutch (Torque) (1) off the ENV Roll

Shaft.



HK

A0N

5FB

24

3 5Parts Reference: ENV Roll Shaft

Continued from p. 373.7. Remove the Bearing (2).8. Move the ENV Roll Shaft (3) to the left and release

it from the right bearing (4) of the ENV Tray Asm.9. Lift the ENV Roll Shaft and remove it from the ENV

Tray Asm.10. Remove the bearing from the right ENV Roll Shaft.11. Remove the E-ring (5) from the right ENV Roll

Shaft.



ENV Top CoverParts Reference: Env Top Cover

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the two screws (1) and then open the ENV

Top Cover (2).4. Disconnect connector P/J412 from the ENV PCB.5. Slide the ENV Top Cover to the left to remove it from

the the ENV Tray Asm.



ENV Tray Asm

1

HK

A0M

2FB

Parts Reference: Env Tray Asm

Removal :1. Slide the ENV Tray Asm (1) from the printer.2. Install the ENV Gear Cover.



ENV Tray ExtensionParts Reference: Env Tray Extension

Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Tray Pinch Roll (p. 378).4. Slide the ENV Tray Extension (1) from the ENV Tray

Asm in diagonal upward direction.



ENV Tray Pinch RollParts Reference: Env Tray Pinch Roll

Removal :1. Remove the ENV Tray Asm (p. 376).2. Slide out the ENV Tray Extension (1).3. Use a small screwdriver to push the shafts of the

ENV Tray Pinch Rolls (2) out of the three rear holesof the ENV Tray Pinch Roll.



Exit AsmParts Reference: Exit Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Controller Cover (p. 348).6. Remove the Left Cover (p. 408).7. Remove the Top Cover (p. 493).8. Remove the PCB Cover Plate (p. 467).9. Remove the Rear Cover Interlock Switch (p. 475).

10. Disconnect connectors P/J32 and P/J31 from theMCU PCB (p. 415).

11. Remove the four screws (1) that hold the Exit Asm(2) to the printer.

12. Remove the Exit Asm.



Exit CoverParts Reference: Exit Cover

Removal :1. Open the Rear Cover Asm.2. Release the Exit Cover (1) by pushing in the two

latches (2) at the rear of the printer.3. Remove the Exit Cover.



Exit MotorParts Reference: Exit Motor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Disconnect MCU plug P/J32.4. Remove the Front Left Cover (p. 395).5. Remove the Rear Cover Asm (p. 473).6. Remove the Controller Cover (p. 348).7. Remove the Left Cover (p. 408).8. Remove the Top Cover (p. 493).9. Remove the PCB Cover Plate (p. 467).

10. Disconnect PJ32 from the MCU.11. Remove the Rear Cover Interlock Switch (p. 475).12. Remove the Exit Asm (p. 379).13. Remove the two screws (1) and then remove the

Exit Motor (2) from the Exit Asm.



Exit Roll 1

2

3

3

1

HK

A03

9FB

Right

Left


Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Rear Cover Interlock Switch (p. 475).7. Lift the tab on Exit Gear-17 (1) and remove it from

Exit Roll 1.8. Use a small screwdriver to remove the bearings (3)

from the Exit Asm.9. Remove the Exit Roll 1 from the Exit Asm.

Note: The four Exit Pinch Rolls will fall out whenthe Exit Roll 1 is removed.

10. Slide the bearings off Exit Roll 1.



Exit Roll 3

1

2

3

3

HK

A03

8FB

Right

Left


Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Rear Cover Interlock Switch (p. 475).7. Lift the tab on Exit Gear-17 (1) and slide Exit

Gear-17 from the Exit Roll 3 (2).8. Use a small screwdriver to remove the left and right

bearings (3) from the Exit Asm.9. Remove Exit Roll 3 from the Exit Asm.

10. Remove the left and right bearings from Exit Roll 3.



Exit Static EliminatorParts Reference: Exit Static Eliminator

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Raise the left end of Exit Static Eliminator (1) up

from the left mounting position of the Exit Asm.7. Slide the right end of Exit Static Eliminator from the

right mounting position of the Exit Asm, and removethe Exit Static Eliminator.



Face-Up Chute

1

1

HK

A08

9FB

2

3

5

6

Parts Reference: Face Up Chute

Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the two screws (6) that hold the Face-Up

Gear Cover (5) to the Rear Cover Asm (3).3. Remove the two screws (1) that hold the Face-Up

Chute (2) to the Rear Cover Asm (3).4. Remove the Face-Up Gear Cover and the Face-Up

Chute.



Fan MotorParts Reference: Fan Motor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J283 (1) from the LVPS.9. Release the harness of the Fan Motor (2) from two

clamps in the printer.10. Remove the four screws (3) that hold the Fan

Motor to the printer.11. Remove the Fan Motor.



Feed Asm

1

1

1

1

HK

A0Y

2FB

2

Parts Reference: Feed Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).

10. Remove the LVPS (p. 412).11. Remove the seven screws (1) that hold the Feed

Asm (2) to the printer.12. Remove the Feed Asm from the printer.



Feed Roll Asm

HK

A0Z

0FB

1

1

2

Parts Reference: Feed Roll Asm

Removal :

1. Remove the Front Cover Asm (p. 391).

2. Remove the 550-Sheet Tray Asm (p. 325).

3. Remove the Front Left Cover (p. 395).

4. Remove the Controller Cover (p. 348).

5. Remove the Left Cover (p. 408).

6. Remove the Top Cover (p. 493).

7. Remove the Right Cover (p. 483).

8. Remove the PCB Cover Plate (p. 467).

9. Remove the Left Handle Plate (p. 409).

10. Remove the LVPS (p. 412).

11. Remove the Feed Asm (p. 387).

12. Disconnect P/J64 (not shown) on the Feed Roll Clutch from theFeed Asm.

13. Remove the four screws (1) that hold the Feed Roll Asm (2) tothe Feed Asm.

14. Remove the Feed Roll Asm.



Feed PCBParts Reference: Feed PCB


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect the following four connectors from the

Feed PCB (1):v P/J64v P/J65v P/J66v P/J67

13. Remove the four screws (2) that hold the FeedPCB to the Feed Asm.

14. Remove the Feed PCB from the Feed Asm.



Feed Tray ConnectorParts Reference: Feed Tray Connector

Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the two screws (1) that hold the Feed Tray

Connector (2) to the Feed Asm.3. Remove the Feed Tray Connector from the Feed

Asm.4. Disconnect P/J671 (3) from the Feed Tray

Connector.



Front Cover Asm

2

1

HK

A06

7FB

4

3 Parts Reference: Front Cover Asm

Removal :1. Open the Front Cover Asm (1).2. Remove the E-clip (2).3. Remove the Front Cover Spring (4) from the Front

Cover Stop (3).4. Remove the Front Cover Stop from the right cover.5. Move the Front Cover Asm to the right to remove it

from the printer.



Front Cover Interlock SwitchParts Reference: Front Cover Interlock Switch

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J284 (1) from the LVPS.9. Unclamp the harness of the Front Cover Interlock

Switch (2) from the printer.10. Remove the two screws (3) that hold the Front

Cover Interlock Switch to the printer.11. Remove the Front Cover Interlock Switch.



Front Duplex Roll

4

2

HK

A0E

2FC

1

3

Parts Reference: Front Duplex Roll

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the front Duplex Roll Retaining Clip (p.

359).8. Remove the Duplex Drive Belt (p. 353).9. Remove the Duplex Gear 17/Pulley (1) from the

Front Duplex Roll (2).10. Use a small screwdriver to remove the left Duplex

Roll Bearing (3) from the left shaft of the FrontDuplex Roll.

11. Use a small screwdriver to remove the right DuplexRoll Bearing (4) from the right shaft of the FrontDuplex Roll.



Parts Reference: Front Duplex Roll

Continued from p. 393.12. Move the Front Duplex Roll (2) to the upper bearing

of the Duplex Asm.13. Move the Front Duplex Roll to the left and remove

the right shaft of the Front Duplex Roll from theDuplex Asm.

14. Lift the right shaft of the Front Duplex Roll andremove the Front Duplex Roll from the Duplex Asm.



Front Left CoverParts Reference: Front Left Cover

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the three screws (1) that hold the Front Left

Cover (2) to the printer.4. Use a screwdriver to release the upper left hook of

the Front Left Cover.5. Remove the Front Left Cover.



Full Stack ActuatorParts Reference: Full Stack Actuator

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Exit Static Eliminator (p. 384).7. Raise the left shaft of Full Stack Actuator (1) to

remove it from the left bearing of the Exit Asm.8. Slide the right shaft of the Full Stack Actuator from

the right bearing of the Exit Asm, and remove theFull Stack Actuator.



Full Stack Photo SensorParts Reference: Full Stack Photo Sensor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Exit Static Eliminator (p. 384).7. Remove the Full Stack Actuator (p. 396).8. Disconnect P/J311 (1) from the Full Stack Photo Sensor

(2).9. Release the hooks that hold the Full Stack Photo Sensor

to the Exit Asm and remove the Full Stack Photo Sensor.



Fuser Asm

2

1

HK

A03

5FA

Right

Left

Parts Reference: Fuser Asm 230 v, Fuser Asm 120 v

Removal :

CAUTION:

<2-43> High temperature; switch off the printer and allow at least 30 minutesfor parts in this area to cool before handling.

hcsf

0243

1. Open the Rear Cover Asm.2. Remove the two screws (1) that hold the Fuser Asm

(2) to the printer.3. Remove the Fuser Asm.



Fuser StopParts Reference: None

Removal :1. Open the Rear Cover Asm (2).2. Pull the Fuser Stops (1) from the left and right holes

of the Face-Up Chute.



Gear Drive AsmParts Reference: Gear Drive Asm

Removal :

1. Remove the Front Cover Asm (p. 391).



4. Open the Rear Cover Asm (p. 473).

5. Remove the Fuser Asm (p. 398).


7. Remove the Controller PCB. (p. 349).



10. Remove the Aux Tray Asm (p. 342).

11. Remove the Aux Drive Gear Shaft and Aux Drive Gear (p. 327).

12. Remove the Toner Cartridge.

13. Remove the Paper Handling Asm (p. 462).

14. Remove the BTR Support Asm (p. 347).



17. Remove the MCU PCB (p. 415).

18. Remove the Main Motor (p. 413)


20. Remove the four screws (1) that hold the Gear Drive Asm (2) tothe printer.

21. Remove the Gear Drive Asm.

Replacement: Reverse the removal procedure.Note: The letter ″D″ is written near the four holes where the Gear DriveAsm screws are mounted.


Harness (J27, J11, J262 - J271)Parts Reference: Harness (J27, J11, J262-J271)

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Fuser Asm (p. 398).6. Remove the Controller Cover (p. 348).7. Remove the Left Cover (p. 408).8. Remove the Top Cover (p. 493).9. Remove the Aux Tray Asm (p. 342).

10. Remove the Aux Drive Gear Shaft (p. 327).11. Remove the Aux Drive Gear (p. 327).12. Remove the Toner Cartridge.13. Remove the Paper Handling Asm (p. 462).14. Remove the BTR Support Asm (p. 347).15. Remove the PCB Cover Plate (p. 467).16. Remove the Left Handle Plate (p. 409).17. Remove the MCU PCB (p. 415).18. Remove the Main Motor (p. 413)19. Remove the LVPS (p. 412).20. Remove the Gear Drive Asm (p. 400).



Parts Reference: Harness (J27, J11, J262-J271),Harness (J27, J11, J262-J271)

Continued from p. 401.21. Disconnect P/J261 on the HVPS.22. Remove the one screw that hold the HVPS

Housing and the HVPS to the printer.23. Remove the HVPS Housing with the HVPS.24. Disconnect P/J27 from the MCU PCB.25. Disconnect P/J11 from the LVPS.26. Pull the Harness (J27, J11, J262 - J271) (1) from

the left hole in the printer.27. Remove the two screws (2) that hold the Harness

(J27, J11, J262 - J271) to the printer.28. Remove the Harness (J27, J11, J262 - J271).

Replacement: Reverse the removal procedure.Note: Do not install Harness (J27, J11, J262 - J271) inthe reversed position. Verify correct installation using theFuser.


Harness (J34-P341)Parts Reference: Harness (J34 - P341):

Removal :1. Remove the Front Cover Asm (p. 391).



4. Open the Rear Cover Asm (p. 473).

5. Remove the Fuser Asm (p. 398).




9. Remove the Aux Tray Asm (p. 342).

10. Remove the Aux Drive Gear Shaft (p. 327).

11. Remove the Aux Drive Gear (p. 327).

12. Remove the Toner Cartridge.

13. Remove the Paper Handling Asm (p. 462).

14. Remove the BTR Support Asm (p. 347).



17. Remove the MCU PCB (p. 415).

18. Remove the Main Motor (p. 413)


20. Remove the Gear Drive Asm (p. 400).

21. Disconnect P/J34 (1) from the MCU PCB.

22. Remove the two screws (2) that hold the Harness (J34-P341) (3)to the printer.

23. Slide the Harness (J34-P341) from the hole in the printer.



Harness (J35 - J351)Parts Reference: Harness (J35 - J351):

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J35 (1) from the MCU PCB.9. Unclamp the Harness (J35 - J351) (2) from the

printer.10. Remove the two screws (3) that hold the Harness

(J35 - J351) to the printer.11. Slide the Harness (J35 - J351) from the hole in the

printer.



Harness (J51 - J511)Parts Reference: Harness (J51 - J511)

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove the Paper Size Housing (p. 464).

10. Disconnect P/J51 (1) of Harness (J51 - J511) (2)from the Paper Sizing PCB.

11. Remove the two screws (3) that hold Harness (J51- J511) to the Paper Size Housing.

12. Slide off the harness of Harness (J51 - J511) fromthe Paper Size Housing, and remove the Harness(J51 - J511).



HVPSParts Reference: HVPS

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the Bias Transfer Roll (p. 346).

10. Remove the BTR Support Asm (p. 347).11. Disconnect P/J261 (1) from the HVPS.12. Remove the one screw (2) that holds the HVPS (3)

and HVPS Housing (4) to the printer.13. Remove the HVPS Housing and the HVPS from the

printer.14. Release the hooks that hold the HVPS to the HVPS

Housing and remove the HVPS.



Interface PCBParts Reference: Interface PCB

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Top Cover (p. 493).5. Disconnect the following connectors from the

Interface PCB (1).v P/J41v P/J42v P/J43v P/J44v P/J45v P/J231

6. Remove the three screws (2) that hold the InterfacePCB to the printer.

7. Remove the Interface PCB.



Left CoverParts Reference: Left Cover

Removal :1. Remove the Controller Cover (p. 348).2. Remove the two screws (1) that hold the Left Cover

(2) to the printer.3. Remove the Left Cover.

Replacement: Reverse the removal procedure. Makesure the Left Cover properly fits with the Top Cover andthe Front Left Cover.


Left Handle PlateParts Reference: None

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the four screws (1) that hold the Left

Handle Plate (2) to the printer.7. Remove the Left Handle Plate.



Left Registration Roll Spring

1

HK

A06

9FC

Parts Reference: Left Registration Roll Spring

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Use a small screwdriver to unhook the Left

Registration Roll Spring (1) from the Left Metal RollBearing.

10. Use a small screwdriver to unhook the LeftRegistration Roll Spring from the UpperRegistration Chute.

11. Slide the Left Registration Roll Springs down.



Lift Control Photo Sensor

1

HK

A0Z

4FB

Parts Reference: None


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect P/J661 from the Lift Control Photo

Sensor (1).13. Release the hooks that hold the Lift Control Photo

Sensor to the Feed Asm, and remove the LiftControl Photo Sensor.



LVPS

1

HK

A06

1FB

2

2

2

28511

283 282

281

284

Parts Reference: LVPS 120V, LVPS 230V

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Remove the Left Handle Plate (p. 409).5. Remove the Main Power Switch (p. 414).6. Disconnect the following connectors from the LVPS

(1):v P/J282v P/J283v P/J284v P/J285v P/J11

7. Remove the four screws (2) that hold the LVPS tothe printer.

8. Remove the LVPS.



Main Motor

3

3

2

3

1

HK

A05

0FB

Parts Reference: Main Motor

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect P/J29 (1) from the MCU PCB.5. Remove the four screws (3) that hold the Main Motor

(2) to the printer.6. Remove the Main Motor.



Main Power Switch

1

1

HK

A07

7FB

Parts Reference: Main Power Switch

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Remove the Left Handle Plate (p. 409).5. Disconnect the harness attached to the LVPS from

the Main Power Switch (1).6. Push the Main Power Switch so that it comes out of

the front of the printer.



MCU PCBParts Reference: MCU PCB

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect the following connectors from the MCU

PCB (1):v P/J21v P/J23v P/J25v P/J26v P/J27v P/J28v P/J29v P/J30v P/J31v P/J32v P/J33v P/J34v P/J35

5. Remove the four screws (2) that hold the MCU PCBto the printer.

6. Remove the MCU PCB.



Metal Registration Roll GearParts Reference: Metal Registration Roll Gear

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Release the E-ring (1) that holds the Metal

Registration Roll Gear (2) to the Paper HandlingAsm.

10. Slide the Metal Registration Roll Gear off the PaperHandling Asm.



Middle Duplex RollParts Reference: Middle Duplex Roll

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the middle Duplex Roll Retaining Clip (p.

359).8. Remove the Duplex Drive Belt (p. 353).9. Remove the Duplex Gear 17/Pulley (1) from the

Middle Duplex Roll (2).10. Remove the Duplex Gear 17/39 (3) from the shaft

of the Duplex Asm.11. Remove the Duplex Gear 18 (4) from the shaft of

the Duplex Asm.12. Use a small screwdriver to remove the left Duplex

Roll Bearing (5) from the left shaft of the MiddleDuplex Roll.

13. Use a small screwdriver to remove the right DuplexRoll Bearing (6) from the right shaft of the MiddleDuplex Roll.



Parts Reference: Middle Duplex Roll

Continued from p. 417.14. Move the Middle Duplex Roll (2) to the upper

bearing of the Duplex Asm.15. Move the Middle Duplex Roll to the left and then

remove the right shaft of the Middle Duplex Rollfrom the Duplex Asm.

16. Lift the right side of the Middle Duplex Roll andthen remove the Middle Duplex Roll from theDuplex Asm.



No Paper Actuator

HK

A0Z

3FB

1

2

Right

Left

Parts Reference: No Paper Actuator


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Unhook the left and right shafts of the No Paper

Actuator (1) from the left and right No PaperActuator Supports (2), and remove the No PaperActuator from the Feed Asm.



Offset Asm

1

HK

A0G

1FA

Parts Reference: Offset Asm

Removal :1. Open the Rear Cover.2. Release the two hooks on the back of the Offset

Asm (1) and remove the Offset Asm.3. If you do not re-install the Offset Asm, install the

Cover Option on the Cover Asm Top.



Offset Direction Solenoid

1

2

3

HK

A0H

2FA

Parts Reference: Offset Direction Solenoid

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Disconnect connector P/J228 (1).9. Remove the two screws (3) that hold the Offset

Direction Solenoid (2) to the Offset Inner Asm.10. Unhook the harness of the Offset Direction

Solenoid from the Offset Inner Asm and remove theOffset Direction Solenoid.



Offset Direction Home Sensor

1

2 HK

A0I

4FB

Parts Reference: Offset Direction Home Sensor

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the Offset Mechanism Asm (432).9. Release the hooks that hold the Offset Direction

Home Sensor (1) to the Offset Asm (2).



Offset Drive Motor

1

1

2

3

HK

A0H

0FA

Right

Left

Parts Reference: Offset Drive Motor

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the two screws (1) that hold the Offset

Drive Motor (2) to the Offset Inner Asm.9. Remove the Offset Drive Motor from the Offset

Inner Asm.10. Disconnect connector P/J210 (3).

Replacement: Reverse the removal procedure.Note: The Offset Drive Motor must be mounted with itsconnector facing the front.


Offset Exit Bin

1 HK

A0G

4FA

2

Parts Reference: Offset Exit Bin

Removal :1. Remove the Offset Exit Asm (p. 425).2. Remove the right shaft of the Offset Exit Bin (1) from

the right hole in the Offset Top Cover (2).3. Remove the left shaft of the Offset Exit Bin from the

left hole in the Offset Top Cover and remove theOffset Exit Bin.



Offset Exit Bin Asm

1

2

HK

A0G

2FA

Parts Reference: Offset Exit Asm

Removal :1. Open the Offset Exit Asm.2. Remove the right side of the Offset Exit Asm (1)

from the right hole in the Offset Top Cover (2).3. Remove the left side of the Offset Exit Asm from the

left hole in the Offset Top Cover, and remove theOffset Exit Asm.



Offset Exit Photo Sensor

1

2

HK

A0H

3FC

Parts Reference: Offset Exit Bin Sensor

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Release the hooks that hold the Offset Exit Photo

Sensor (1) to the Offset Inner Asm.9. Disconnect connector P/J227 (2) from the Offset Exit

Photo Sensor.



Offset Full Stack Actuator

1

HK

A0H

4FB

Parts Reference: Offset Full Stack Actuator

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the left shaft of the Offset Full Stack

Actuator (1) from the Offset Inner Asm.9. Release the right shaft of the Offset Full Stack

Actuator from the Offset Inner Asm, and remove theOffset Full Stack Actuator.



Offset Full Stack Photo Sensor

12

HK

A0H

5FA

Right

Left

Parts Reference: Offset Full Stack Photo Sensor

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the Offset PCB (p. 434).9. Disconnect connector P/J225 (1) from the Offset

Full Stack Photo Sensor (2).10. Release the hooks that hold the Offset Full Stack

Photo Sensor to the Offset Inner Asm and removethe Offset Full Stack Photo Sensor.



Offset Inner Asm

32

1

2

HK

A0G

8FB

Bottom

Top

Parts Reference: Offset Inner Asm

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover (1).6. Remove the Offset Lower Cover (p. 431).7. Remove the five screws (2) that hold the Offset Inner

Asm (3) to the Offset Asm.8. Remove the Offset Inner Asm from the Offset Asm.



Offset Inner Chute Cover

1

1

2

HK

A0I

0FB

Bottom

Top

Parts Reference: Offset Inner Chute Cover

Removal :1. Remove the four screws (1) that hold the Offset

Inner Chute Cover (2) to Offset Inner Asm.2. Remove the Offset Inner Chute Cover.



Offset Lower Cover

11

2

3

HK

A0I

1FB

Bottom

Top

Parts Reference: Offset Lower Cover

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the six screws (1) that hold the Offset

Lower Cover (2) to the Offset Inner Asm.7. Remove the Offset Lower Cover from the Offset

Inner Asm.



Offset Mechanism Asm

1

2 3

HK

A0I

2FC

Parts Reference: Offset Asm

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Unhook the Offset Lever (1) from the Offset Inner

Asm.9. Remove the two screws (2) and then remove the

Offset Asm (3) from the Offset Inner Asm.10. Disconnect connector P/J226 from the Offset

Direction Home Sensor.11. Disconnect connector P/J210 of the Offset Motor.12. Unclamp the harness of the Offset Motor at two

places from the Offset Inner Asm.13. Remove the Offset Asm from the Offset Inner Asm.



Offset Paper Weight

1

HK

A0G

5FB

Parts Reference: Offset Paper Weight

Removal :1. Squeeze the left and right brackets of the Offset

Paper Weight (1) and remove it from the Offset Asm.



Offset PCB

1

2

HK

A0G

9FA

Right

Left

Parts Reference: Offset PCB

Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the one screw (1) that holds the Offset

PCB (2) to the Offset Inner Asm.9. Disconnect the following connectors from the Offset

PCB.v P/J223v P/J210v P/J224v P/J209

10. Remove the Offset PCB.



Offset Rear Cover

1 HK

A0G

6FBRight

Left

Parts Reference: Offset Rear Cover

Removal :1. Open the Offset Rear Cover (1).2. Use a small screwdriver to remove the right bracket

of the Offset Rear Cover from the right hole in theOffset Top Cover.

3. Slide the left shaft of the Offset Rear Cover from theleft hole in the Offset Top Cover, and remove theOffset Rear Cover.



Offset Tray Spring

1

HK

A0G

3FB

2 Parts Reference: Offset Tray Spring

Removal :1. Remove the Offset Exit Asm (p. 425).2. Remove the Offset Exit Bin (p. 424).3. Turn the right Offset Tray Spring (1) to the left

(counter-clockwise), remove it from the hook of theOffset Asm.

4. Turn the left Offset Tray Spring (2) to the left(counter-clockwise), remove it from the hook of theOffset Asm.



Operator Panel

2

1 1

3 HK

A08

3FA

Parts Reference: Operator Panel

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the Top Cover (p. 493).6. Remove the four screws (1) that hold the Operator

Panel (2) to the Top Cover.7. Remove the Operator Panel from the Top Cover.8. Disconnect the Harness (J4-Operator Panel) (3) from

the Operator Panel.



Option Chute SpringParts Reference: None

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the Option Feed Roll Asm (p. 441).8. Unhook the Option Chute Spring from the Option

Feed Roll Asm (2), and remove the Option ChuteSpring.



Option Feed AsmParts Reference: Option Feed Asm

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the six screws (1) and remove the Option

Feed Asm (2) from the Option 550-Sheet Asm.



Option Feed PCBParts Reference: Option Feed PCB

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect the following connectors on the Option

Feed PCB (1) from the Option Feed Asm.:v P/J64v P/J65v P/J66v P/J67

8. Remove the four screws (2) and then remove theOption Feed PCB from the Option Feed Asm.



Option Feed Roll AsmParts Reference: Option Pick Roll Asm

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J641 on the Option Feed

Roll Clutch from the Option Feed Asm.8. Remove the four screws (1) that hold the Option

Feed Roll Asm (2) to the Option Feed Asm.9. Remove the Option Feed Roll Asm.



Option Gear BracketParts Reference: Option Gear Bracket

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the five screws (1) that hold the Option

Gear Bracket (2) to the Option Paper Drawer.3. Remove the Option Gear Bracket from the Option

Paper Drawer.



Option Harness (J52-J521)Parts Reference: Option Harness (J52 - J521)

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the two screws (1) that hold the Option

Harness (J52-J521) (2) to the Option Paper Drawer.4. Insert the Option Harness (J52-J521) into the hole in

the Option Paper Drawer.



Parts Reference: Option Harness (J52 - J521)

Continued from p. 443.5. Use a small screwdriver to push one boss that holds

the Option Paper Sizing Sensor Asm (3) to theOption Paper Drawer to release the boss from thehole.

6. Slide the Option Paper Sizing Sensor Asm andOption Harness (J52-J521) (2) to the rear from theOption Paper Drawer.

7. Remove the Option Paper Sizing Sensor Cover (p.451).

8. Disconnect connector P/J52 (4) of the OptionHarness (J52-J521).

9. Remove the Option Paper Sizing Sensor Asm fromthe Option Paper Drawer.



Option Harness (J53-531)Parts Reference: Option Harness (J53 - J531)

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the Option Paper Size Front Cover (p. 451).6. Disconnect connector P/J53 (1) from the Option

Paper Size PCB.7. Remove the two screws (2) that hold the Option

Harness (J53-531) (3) to the Option Paper SizeSensor Asm.

8. Remove the Option Harness (J53-531) from theOption Paper Size Sensor Asm.



Option Left CoverParts Reference: Option Left Cover

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the four screws (1) that hold the Option Left

Cover (2) to the Option Paper Drawer.3. Gently lift the left side of Option Paper Drawer and

then remove the Option Left Cover.



Option Lift Control Photo Sensor

1

HK

A0B

3FD

2


Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J662 (1) from the Option Lift

Control Photo Sensor (2).8. Release the hooks and remove the Option Lift

Control Photo Sensor.



Option No Paper ActuatorParts Reference: Option No Paper Actuator

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Unhook the left and right shafts of Option No Paper

Actuator (1) from the left and right Option No PaperActuator Supports (2), and remove the Option NoPaper Actuator from the Option Feed Asm.



Option Paper DrawerParts Reference: Option Paper Drawer

Removal :1. Remove the three screws (1) that hold the Option

Paper Drawer (2) to the printer.2. Lift the printer off of the drawer.

CAUTION:

<2-41> The printer weighs approximately 28 kg (62 lb). Use two personsto carry the printer. Use appropriate lifting precautions.

hcsf

0241



Option Paper Low Photo Sensor

1

HK

A0B

3FC

2

Parts Reference: Option Paper Low Photo Sensor

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J661 (1) from the Option

Paper Low Photo Sensor (2).8. Release the hooks and remove the Option Paper

Low Photo Sensor.



Option Paper Size Front Cover

1

1

HK

A0C

2FB

2

3

4

Front

Rear

Parts Reference: Option Paper Size Front Cover

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the four screws (1) that hold the Option

Paper Size Front Cover (2) to the Option Paper SizeSensor Asm (3).

6. Release two hooks (4) and remove the Option PaperSize Front Cover from the Option Paper Size SensorAsm.



Option Paper Size PCBParts Reference: Option Paper Size PCB

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the Option Paper Size Front Cover (p. 451).6. Disconnect connector P/J53 from the Option Paper

Size PCB (1).7. Remove the two screws (2) and remove the Option

Paper Size PCB from the Option Paper Size SensorAsm.



Option Paper Size Sensor Asm

2

HK

A0A

4FA

3

1 Parts Reference: Option Paper Size Sensor Asm

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the two screws that hold the Option

Harness (J52-J521) (2) to the Option Paper Drawer.4. Insert the Option Harness (J52-J521) into the hole in

the Option Paper Drawer.5. Use a small screwdriver to push the one boss (4)

through the hole in the Option paper drawer.6. Remove the Option Paper Size Sensor Asm (3) and

the Option Harness (J52-J521) (2) from the OptionPaper Drawer.



Option Pick Clutch - ElectricParts Reference: Option Pick Clutch - Electric

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the four screws (1) and then remove the

Option Gear Bracket (2) from the Option Feed Asm.8. Slide the Option Gear 3 (3) from the shaft of the

Option Feed Asm.9. Slide the Option Gear 2 (4) from the shaft of the

Option Feed Asm.



Parts Reference: Option Pick Clutch - Electric

Continued from p. 454.10. Disconnect connector P/J65 (5).11. Release the E-ring (6) and slide the Option Pick

Clutch - Electric (7) from the shaft of Option PickRoll Asm.



Option Pick RollParts Reference: Option Pick Roll

Removal :1. Slide the Option 550-Sheet Tray Asm from the

Option Paper Drawer.2. Open the Option Feed Position Plate (1).3. Unhook the latches on the Option Pick Rolls (2), and

slide them off the shafts of the Option Pick Roll Asm.



Option Pick Roll AsmParts Reference: Option Pick Roll Asm

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the Option Pick Clutch - Electric (p. 454).8. Release the E-ring (1).9. Slide the bearing (3) off the left shaft of the Option

Pick Roll Asm (2).



Parts Reference: Option Pick Roll Asm

Continued from p. 457.10. Open the Option Feed Position Plate (4).11. Slide the Option Pick Roll Asm (2) to the right to

remove it from the Option Feed Asm. Be careful notto lose the spring (5).



Option Right CoverParts Reference: Option Right Cover

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the four screws (1) that hold the Option

Right Cover (2) to the Option Paper Drawer.3. Raise the right side of Option Paper Drawer slightly.

Then remove the Option Right Cover.



Option SocketParts Reference: Option Socket

Removal :1. Remove the Option 550-Sheet Tray Asm.2. Remove the two screws (1) and then remove the

Option Socket (2) from the Option Feed Asm.3. Disconnect connector P/J71 (3) from the Option

Socket.



Option Top Front PlateParts Reference: Option Top Front Plate

Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the one screw (1) that holds the Option Top

Front Plate (2) to the Option Paper Drawer.6. Remove the Option Top Front Plate from the Option

Paper Drawer.



Paper Handling AsmParts Reference: Paper Handling Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Disconnect P/J42 and P/J43 (1) from the Interface

PCB.9. Release two clamps from the harness of the Paper

Handling Asm.10. Remove the five screws (2) that hold the Paper

Handling Asm (3) to the printer.11. Lift the right side of the Paper Handling Asm and

then slide it to the right to remove.



Paper Low Photo Sensor

HK

A0Z

4FC

Parts Reference: Paper Low Photo Sensor


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect P/J662 from the Paper Low Photo

Sensor (2).13. Release the hooks that hold the Paper Low Photo

Sensor to the Feed Asm, and remove the PaperLow Photo Sensor.



Paper Size Housing

1

1

HK

A05

4FB

2

3

4

Front

Rear

Parts Reference: Paper Size Housing

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove four screws (1) that hold the Paper Size

Housing (2) to the Paper Size Housing Asm (3).10. Release two hooks (4) and remove the Paper Size

Housing from the Paper Size Housing Asm.



Paper Size Housing Asm

1

HK

A05

3FA

2

3

Parts Reference: Paper Size Sensor Asm

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Disconnect P/J33 (1) from the MCU PCB.9. Release three clamps that hold Harness P/J33 -

P/J331 to the printer frame.10. Use a small screwdriver to push a peg (3) and slide

the Paper Size Housing Asm to the rear.11. Slide the harness of the Paper Size Housing Asm

from the hole in the printer.



Paper Sizing PCBParts Reference: Paper Size PCB

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove the Paper Size Housing (p. 464).

10. Remove the two screws (1) that hold the Paper SizingPCB (2) to the Paper Size Housing.

11. Remove the Paper Sizing PCB from the Paper SizeHousing.

12. Disconnect P/J51 from the Paper Sizing PCB.13. Disconnect P/J331 from the Paper Sizing PCB.



PCB Cover PlateParts Reference: None

Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the six screws (1) that hold the PCB Cover

Plate (2) to the printer.4. Remove the PCB Cover Plate.



Pick Clutch - Electric

1

3

HK

A0Z

9FB

2

Right

Left5

4

Parts Reference: Pick Clutch - Electric


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Remove the one screw that holds clamp (5) to the Feed

Bracket (2), and remove the clamp.13. Remove the three screws (1) that hold the Feed Bracket

to the Feed Asm, and remove the Feed Bracket from theFeed Asm.

14. Slide the Feed Gears (3, 4) off the shafts of the FeedAsm.



HK

A0Y

0FA

Right

Left

67

8

Parts Reference: Pick Clutch - Electric

Continued from p. 468.15. Remove the E-ring (6) and then slide the Pick Clutch -

Electric (7) off the shaft of the Pick Roll Asm.16. Disconnect P/J65 (8) from the Feed PCB.



Pick RollParts Reference: Pick Roll

Removal :1. Remove the 550-Sheet Tray Asm.2. Open the Feed Position Plate (1).3. Unhook the latch on the front Pick Roll (2) and slide

it off the front shaft of the Pick Roll Asm.4. Unhook the latch on the rear Pick Roll (2) and slide

it off the rear shaft of the Pick Roll Asm.



Pick Roll Asm

1

HK

A0Z

5FB

2

3

Parts Reference: Pick Roll Asm


10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Remove the Pick Clutch - Electric (p. 468).13. Release the E-ring (1), and then slide the bearing

(2) from the shaft of the Pick Roll Asm (3).



35

HK

A0Z

6FC

4

Right

Top

Left

Parts Reference: Pick Roll Asm

Continued from p. 471.14. Open the Feed Position Plate (4) from the Feed

Asm.15. Slide the shaft of the Pick Roll Asm (3) off of the

bearing hole, and remove it from the Feed Asm. Becareful not to lose the spring (5).



Rear Cover AsmParts Reference: Rear Cover Asm (With Face-Up Bin),Rear Cover Asm (Without Face-Up Bin)

Removal :1. Open the Rear Cover Asm (1).2. Slide the lead edge of the Rear Cover Stop (not

shown) from the Rear Cover Asm and remove thestrap.

3. Pull the Rear Cover Pivot Stop (2) and slide theRear Cover Asm off the pivot shafts of the printer.



Rear Cover Interlock SwitchParts Reference: Rear Cover Interlock Switch

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Controller Cover (p. 348).6. Remove the Left Cover (p. 408).7. Remove the Top Cover (p. 493).8. Remove the PCB Cover Plate (p. 467).9. Remove the Rear Cover Interlock Switch (p. 475).

10. Remove the Exit Asm (p. 379).11. Disconnect P/J30 (1) from the MCU PCB.12. Unclamp the harness of the Rear Cover Interlock

Switch (2) from the printer.13. Remove the two screws (3) that hold the Rear

Cover Interlock Switch to the printer.14. Slide the harness of the rear cover switch from the

hole in the printer.



Rear Cover Interlock SwitchParts Reference: Rear Cover Interlock Switch

Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the three screws (1) that hold the Rear

Cover Interlock Switch (2) to the printer.3. Remove the Rear Cover Interlock Switch.



Rear Cover StopParts Reference: Rear Cover Stop

Removal :1. Open the Rear Cover Asm.2. Remove the one screw (1) that holds the Rear Cover

Stop (2) to the printer.3. Remove the Rear Cover Stop from the Rear Cover

Asm.



Rear Duplex Roll

1 5

HK

A0D

6FC

6

4 3

2

Parts Reference: Duplex Roll

Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Motor (p. 355).6. Remove the Duplex Upper Guide (p. 361).7. Remove the Duplex Roll Retaining Clip (p. 359).8. Remove the Duplex Gear 17/Pulley (1) from the

Duplex Roll (2).9. Remove the Duplex Gear 17/39 (3) from the shaft

of the Duplex Asm.10. Remove the Duplex Gear 18 (4) from the shaft of

the Duplex Asm.11. Use a screwdriver to remove the left Duplex Roll

Bearing (5).12. Use a screwdriver to remove the right Duplex Roll

Bearing (6).13. Move the the Rear Duplex Roll to the front bearing

of the Duplex Asm.



Parts Reference: Duplex Roll

Continued from p. 477.14. Slide the Rear Duplex Roll to the left and remove

the right shaft of the Rear Duplex Roll from theDuplex Asm.

15. Lift the right side of the Rear Duplex Roll and thenremove it from the Duplex Asm.



Registration Actuator

HK

A02

4FA

2

3

1

Parts Reference: Registration Actuator

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute (3).

10. Release the right hook of the Registration Actuator Spring (1)from the Paper Handling Asm.

11. Move the lever of the Registration Actuator (2) to the left torelease the right shaft of Registration Actuator.

12. Remove the Registration Actuator.



Registration Actuator Spring

HK

A02

4FA

2

3

1

Parts Reference: Registration Actuator Spring

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute (3).

10. Release the right hook of the Registration Actuator Spring (1)from the Paper Handling Asm.

11. Hold the operating lever of the Registration Actuator (2) andmove it to the left to remove the right shaft of theRegistration Actuator.

12. Remove the Registration Actuator Spring from the shaft ofthe Registration Actuator.



Registration Clutch - Electric

HK

A02

7FC

2

1

3

Right

Left

Parts Reference: Registration Clutch - Electric

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Disconnect P/J433 (1) from the Registration Clutch

- Electric (2).10. Release the E-ring (3) and slide the Registration

Clutch - Electric from the Paper Handling Asm.



Registration SensorParts Reference: Registration Sensor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute and the Toner

Sensor Bracket from the Paper Handling Asm.10. Remove the Registration Actuator (p. 479)11. Disconnect P/J432 from the Registration Sensor.12. Release the hooks that hold the Registration

Sensor (1), and remove the Registration Sensorfrom the rear side of the Paper Handling Asm.



Right CoverParts Reference: Right Cover

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the Top Cover (p. 493).6. Remove the four screws (1) that hold the Right

Cover (2) to the printer.7. Release the two hooks at the top of the Right Cover

from the holes in the printer.8. Release the two hooks at the bottom of the Right

Cover from the holes in the printer.

Replacement: Reverse the removal procedure. Makesure the Right Cover properly fits with the Top Cover.


Right Registration Roll Spring

1

HK

A06

9FD

Parts Reference: Right Registration Roll Spring

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Use a small screwdriver to unhook the Right

Registration Roll Spring (1) from the Right MetalRoll Bearing.

10. Use a small screwdriver to unhook the RightRegistration Roll Spring from the UpperRegistration Chute.

11. Slide the Right Registration Roll Springs down.



ROS Asm (Laser)Parts Reference: ROS Asm (Laser)

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Disconnect P/J223 from the ROS Asm (Laser) (1).7. Disconnect P/J213 from the ROS Asm (Laser).8. Disconnect P/J212 from the ROS Asm (Laser).9. Remove the four screws (2) that hold the ROS Asm

(Laser) to the printer.10. Slightly raise the ROS Asm (Laser) and disconnect

P/J211 from the bottom.11. Remove the ROS Asm (Laser).



Rubber Registration RollParts Reference: Rubber Registration Roll

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the Left Registration Roll Spring (p. 410).

10. Remove the Right Registration Roll Spring (p. 484).11. Remove the Metal Registration Roll Gear (p. 416).12. Remove the Rubber Registration Roll Gear (p.

489).13. Remove the Registration Clutch - Electric (p. 481).14. Release the left E-ring (1) that holds the Metal

Registration Roll to the Paper Handling Asm.15. Unhook the Chute Torsion Spring from the notch of

Front Registration Chute.16. Move the Chute Torsion Spring to the left from the

Paper Handling Asm, avoiding the boss of RightMetal Roll Bearing (3).



Parts Reference: Rubber Registration Roll

Continued from p. 486.17. Closing the Front Registration Chute and Rear

Registration Chute, align the boss of Right MetalRoll Bearing with the right slit, and slide the RightMetal Roll Bearing from the Paper Handling Asm.

18. Closing the Front Registration Chute and RearRegistration Chute, align the boss of Left Metal RollBearing with the left slit, and slide the Left MetalRoll Bearing (2) from the Paper Handling Asm.

19. Slide upward the right shaft of Metal RegistrationRoll from the right bearing of Paper Handling Asm.

20. Slide diagonally and to the right the MetalRegistration Roll, the Front Registration Chute, andthe Rear Registration Chute from the PaperHandling Asm.



Parts Reference: Rubber Registration Roll

Continued from p. 487.21. Remove the Right Rubber Roll Bearing (4) and the

Left Rubber Roll Bearing (6).22. Move the Rubber Registration Roll (5) to the right

and remove the left shaft of Rubber RegistrationRoll from the Paper Handling Asm.

23. Remove the right shaft of the Rubber RegistrationRoll from the Paper Handling Asm, and remove theRubber Registration Roll.



Rubber Registration Roll GearParts Reference: Rubber Registration Roll Gear

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Release the E-ring (1) that holds the Rubber

Registration Roll Gear (2) from the Paper HandlingAsm.

10. Slide the Rubber Registration Roll Gear off thePaper Handling Asm.



Toner Cartridge Key Sensor

1

2

HK

A04

6FA

Left

Right

Back Side

Parts Reference: Toner Cartridge Key Sensor

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Remove the Toner Cartridge Top Guide (p. 491)9. Release the Harness (1) of the Toner Cartridge Key

Sensor from three clamps of the Toner CartridgeTop Guide.

10. Use a small screwdriver to remove the right shaft ofthe Toner Cartridge Key Sensor (2) from the rightbracket of the Toner Cartridge Top Guide.

11. Use a small screwdriver to remove the left shaft ofthe Toner Cartridge Key Sensor from the leftbracket of the Toner Cartridge Top Guide.



Toner Cartridge Top GuideParts Reference: Toner Cartridge Top Guide

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J25 from the MCU PCB (p. 415).9. Remove the two screws (1) that hold the Toner

Cartridge Top Guide (2) to the printer.10. Remove the Toner Cartridge Top Guide from the

printer.



Toner Sensor AsmParts Reference: Toner Sensor Asm

Removal :1. Open the Front Cover Asm (p. 391).2. Remove the left side of the Toner Sensor Asm (1)

from the Paper Handling Asm.3. Remove the right side of Toner Sensor Asm from the

Paper Handling Asm.4. Disconnect P/J421 (2) from the Toner Sensor Asm.



Top CoverParts Reference: Top Cover

Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the four screws (1) that hold the Top Cover

(2) to the printer.6. Raise the Top Cover slightly. Then disconnect

P/J363 (not shown) from the bottom of the OperatorPanel.

7. Remove the Top Cover.

Replacement: Reverse the removal procedure. Makesure the Top Cover properly fits with the Left Cover,Controller Cover, and Right Cover.


Tray ConnectorParts Reference: Tray Connector

Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the four screws (1) that hold the two Tray

Motor Brackets (2, 4) to the 550-Sheet Tray Asm.3. Remove the two Tray Motor Springs (3, 5) from the

550-Sheet Tray Asm.



6 HK

A09

8FC

10

7

9

8

Right

Left

Parts Reference: Tray Connector

Continued from p. 494.4. Disconnect P/J673 (8) from the Tray Connector (7).5. Remove the two screws (6) that hold the Tray

Connector Guide (10) to the 550-Sheet Tray Asm.6. Remove the Tray Connector and the Tray Connector

Guide from the 550-Sheet Tray Asm.7. Remove the Tray Connector Spring (9).8. Slide the Tray Connector upward, and then

disconnect it from the Tray Connector Guide.



Tray Lift Motor AsmParts Reference: Tray Lift Motor

Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the four screws (1) that hold the two Tray

Motor Brackets (2, 4) to the 550-Sheet Tray Asm.3. Remove the two Tray Motor Springs (3, 5) from the

550-Sheet Tray Asm.



Parts Reference: Tray Lift Motor

Continued from p. 496.4. Disconnect P/J673 (6) from the Tray Connector.5. Remove the three screws (8).6. Remove the Tray Lift Motor Asm (7).

Replacement: Reverse the removal procedure.Note: During installation, make sure the Tray Lift MotorAsm properly fits with the Tray Lift Shaft.


Tray Retard Clutch - FrictionParts Reference: Tray Retard Clutch - Friction

Removal :1. Remove the 550-Sheet Tray Asm.2. Release the left and right latches (1) of the

550-Sheet Tray Asm and open the Tray RetardChute (2).



Parts Reference: Tray Retard Clutch - Friction

Continued from p. 498.3. Remove the Tray Retard Roll (p. 500).4. Slide the Tray Retard Clutch (Friction) (3) off the

Tray Retard Shaft (4).



Tray Retard RollParts Reference: None






Continued from p. 500.3. Unhook the latch on the Tray Retard Roll (3) and

slide the Tray Retard Roll off the Tray Retard Shaft(4).



Tray Retard SpringParts Reference: Tray Retard Spring





4

3

HK

A09

5FB

Right

Left

Parts Reference: Tray Retard Spring

Continued from p. 502.3. Open the Tray Retard Bracket (3).4. Remove the Tray Retard Spring (4).



Chapter 6. Parts Catalog

Using the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Approved Cleaners and Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514

Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519Assembly 4: 550-Sheet Tray Asm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521Assembly 5: 550-Sheet Tray Asm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523Assembly 6: Paper Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526Assembly 7: Aux Tray Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530Assembly 8: P/H Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533Assembly 9: Chute Transfer and Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536Assembly 10: Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538Assembly 11: Drive and Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541Assembly 12: Frame and Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543Assembly 13: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546Assembly 14: Optional Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549Assembly 15: Optional Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552Assembly 16: Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556Assembly 17: Envelope Feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559Assembly 18: Duplex 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562Assembly 19: Duplex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564Assembly 20: Offset Output Bin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Assembly 21: Offset Output Bin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569

Parts Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5735 V DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573


Actuator And Support Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Aux Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Drive Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bearing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Coax NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Compact Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Face-up Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env No-Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Ethernet NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Chute Pinch Roll Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583

Chapter 6. Parts Catalog 505

Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Font Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 120 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 230 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Harness (AC - J285) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J1 - J101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J21 - J211, J212, J213) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J22 - J223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J23 - J231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J25 - J251) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J26 - J261) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J27, J11, J262-J271). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J28 - J281) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J282 - J9, J288 - J9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J31 - J311). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J33 - J331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J34 - J341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J34 - P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J4 - Operator Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594


Harness (J42 - J421) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J43 - J432, J433) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J45 - J451) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J66 - J661, J662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596IBM AFP/IPDS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 120V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 230V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Memory DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Exit Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604


Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Top Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Rear Cover Asm (With Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Asm (Without Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Token Ring NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614


Twinax NIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614


Using the Parts CatalogA table describing the individual assembly parts follows each assembly illustration. A description of the tableentries follows:

Asm.–Index Part Number Description

1– 63H0000 Cover asm. (Contains 100-1, -4)

–1 63H0001 Front Cover

–2 63H0002 Top Cover

–3 N/P Left Top Cover Hinge

–4 N/P Top Cover Right Hinge

–99 63H0003 Kit, top cover mounting with 3 and 4

Asm– Index

Each number in this column corresponds to a number in the assembly illustration.

Part Number

This is the IBM part number for the part listed in the Asm– Index column. ″N/P″ (not procurable) in this columnindicates the part cannot be ordered individually. Order the subassembly or assembly to which the part belongs.

Description

This is a description of the assembly or part.


Approved Cleaners and Lubricants

Table 93. Approved Cleaners and Lubricants

Cleaner orLubricant Use Part

Number Remarks

Cleaner Cleaning metal parts 2286522 Solvent based cleaner

Cover cleaner Cleaning plastic, rubber, and external parts 6933028 Water based, mild detergent

Grease Lubricating Gear teeth 1280441 General purpose grease, medium weight

Oil Lubricating gear shafts and bearings 1280443 General purpose oil, medium weight


Optional FeaturesThe following table lists the part numbers that customer engineers can order to replace defective featureelectronic parts.

If a customer wants to order optional features, they should contact an IBM Authorized Dealer or IBM SalesRepresentative.Table 94. Optional Features

Feature Feature Number Part Number

Paper Drawer/550-Sheet A4/Letter 4501 38L1395

550-Sheet Tray - A4/Letter (extra) 4503 38L1396

Offset Output Bin 4620 38L1398

Envelope Feeder 4620 38L1397

Duplex Unit 4402 38L1394

IBM Infoprint Token Ring 4/16 PCI Adapter (Token-Ring NIC) 4120 02N8367

IBM Infoprint Ethernet 10/100 PCI Adapter (Ethernet NIC) 4162 02N8368

IBM AFP/IPDS Module 4820 02N6723

IBM Coax SCS Interface (Coax NIC) 4171 02N8370

IBM Twinax SCS Interface (Twinax NIC) 4141 02N8369

32MB Memory DIMM 4332 38L1405



Hard Drive 4328 38L1408

PC Parallel Cable (Type C) 4180 38L1409

6 foot US (Chicago) Line Cord 9250 63H5828


Table 94. Optional Features (continued)

Feature Feature Number Part Number

Resource Flash Memory Module 4032 02N6434


Printer Assemblies

Assembly 1: Covers 1


Asm. -Index Part Number Description

1-01 02N6691 Left Cover

-02 02N6692 Controller Cover

-04 02N6693 Exit Cover

-05 02N6694 Top Cover (includes 1-23)

-06 02N6695 Operator Panel (includes 1-07)

-07 02N6696 Operator Panel Harness

-08 02N6697 Right Cover

-09 02N6698 Front Cover Asm (includes 1-10 to 1-13, 1-15 to 1-17, and 1-20)

-10 Front Cover Panel

-11 Front Cover Left Latch

-12 Front Cover Lever

-13 Front Cover Right Latch

-14 02N6699 Front Cover Stop

-15 Front Cover Env Chute

-16 02N6700 Aux Tray Stop

-17 02N6701 Aux Tray

-19 02N6702 Front Left Cover

-20 Aux Tray Paper Guide

-21 Env Gear Cover

-22 Aux Tray Stop Clip

-23 Top Cover Earth Spring

-24 Front Cover Stop Spring Joint



-25 Front Cover Stop Spring



99 (with1~9)

98 (7(2x))



2-01 Rear Cover Latch Spring (same as 3-02)

-02 Rear Cover Left Latch (same as 3-03)

-03 Rear Cover Right Latch (same as 3-04)

-04 Rear Cover Latch Guide (same as 3-05)

-05 Rear Cover Plate (same as 3-06)

-06 Rear Cover Arm (same as 3-12)

-07 Fuser Stop (same as 3-17)

-08 Rear Cover Chute

-09 Rear Cover Pivot Stop (same as 3-14)

-10 02N6704 Rear Cover Stop (same as 3-16)

-11 Duplex Left Guide Rail

-12 Duplex Right Guide Rail

-13 Face-Up Cover

-98 Fuser Stop Kit (includes 2 x 2-07)

-99 02N6705 Rear Cover Asm (Without Face-Up Bin) (includes 2-01 to 2-09 and 2-13 )



3-01 38L1399 Rear Cover Asm (With Face-Up Bin) (includes 3-02 to 3-15, 3-17 to 3-19)

-02 Rear Cover Latch Spring (same as 2-01)

-03 Rear Cover Left Latch (same as 2-02)

-04 Rear Cover Right Latch (same as 2-03)

-05 Rear Cover Latch Guide (same as 2-04)

-06 Rear Cover Plate (same as 2-05)

-07 Face Up Bin Extension

-08 Face Up Bin

-10 Pinch Roller Spring (same as 10-14)

-11 Pinch Roller (same as 10-12)

-12 Face Up Direction Lever (same as 2-06)

-13 02N6707 (notstocked)

Face Up Chute

-14 Rear Cover Pivot Stop (same as 2-09)

-15 Ground Spring

-16 02N6704 Rear Cover Stop (same as 2-10)

-17 Fuser Stop (same as 2-07)

-18 Rear Cover Chute Cover

-19 Face-Up Bin Static Eliminator


Assembly 4: 550-Sheet Tray Asm 1

Same as 5-01



4-01 38L1396 550-Sheet Tray Asm (includes 4-02 to 4-23)

-02 Tray Paper Support Plate

-05 Tray Paper Length Stop

-06 Tray Housing Extension

-07 Tray Paper Length Position

-08 Tray Paper Length Spring

-09 Tray Latch Spring

-10 Tray Paper Length Plate

-11 Tray Base Extension

-12 Tray Left Paper Width Plate

-13 Tray Right Paper Width Plate

-14 Tray Link

-15 Tray Base Plate

-16 Tray Paper Width Rack

-17 Tray Paper Width Pinion

-18 Tray Sub Asm (same as 5-01)

-19 Tray Paper Length Actuator

-20 Tray Paper Length Actuator Cover

-21 Tray Button Label

-22 Tray Indicator Label

-23 Tray Base Plate Label


Assembly 5: 550-Sheet Tray Asm 2

Same as 4-18



5-01 Tray Sub Asm (same as 4-18) (includes 5-02 to 5-27)

-02 Tray Retard Chute Latch Cover

-03 Tray Retard Chute Left Latch

-04 Tray Retard Chute

-05 Tray Retard Chute Right Latch

-06 Tray Retard Shaft

-07 02N6710 Tray Retard Clutch - Friction

-08 Tray Retard Roll

-09 Tray Retard Bracket

-10 02N6711 Tray Retard Spring

-11 Tray Lift Plate

-12 Tray Lift Shaft

-13 Tray Lift Shaft Support

-14 Bearing

-15 Tray Lift Shaft Ground Spring

-16 Tray Housing

-17 Tray Paper Empty Display Lever

-18 Tray Front Cover

-19 Tray Motor Spring

-20 Tray Right Motor Bracket

-21 Tray Left Motor Bracket

-22 02N6712 Tray Lift Motor



-24 Tray Lift Motor Support


Tray Connector

-26 Tray Connector Spring

-27 Tray Connector Guide


Assembly 6: Paper Feeder

45

98 (with2~40)

96 (with39,40)

97 (with11,12)

98 (with26 (3x) and 5.08)



6-01 02N6714 Feed Roll Asm (includes 6-02)

-02 Feed Roll Clutch

-03 Feed Roll Spring

-04 02N6715 Feed Roll Chute Spring

-05 Feed Roll Chute Cover


No Paper Actuator

-07 No Paper Actuator Support

-08 Feed Frame

-09 Feed Clamp

-10 Feed Latch Spring

-11 Low Paper Actuator

-12 Low Paper Actuator Support

-13 02N6717 Paper Low Photo Sensor


Harness (J66 - J661, J662)

-15 Feed Position Plate

-17 Feed Chute Pinch Roll

-18 Feed Cover

-19 02N6719 Pick Roll Asm (includes 6-20 to 6-29)

-20 Pick Roll Shaft

-21 Bearing



-22 Pick Roll Support

-23 Pick Roll Clutch

-24 Pick Roll Clutch Support

-25 Pick Roll Clutch Interlock

-26 Pick Roll

-27 Pick Gear 25T

-28 Pick Gear 31T

-29 Pick Roll Support Spring

-30 Feed Gear 4

-31 Feed Gear 2

-32 Feed Gear Cover

-33 Feed Bracket

-34 Feed Gear 3

-35 Feed Gear 1

-36 02N6720 Feed PCB

-37 02N6721 Pick Clutch - Electric

-38 Bearing

-39 Harness (J67 - J671)

-40 Pick Tray Connector

-41 Feed Chute Pinch Roll Support

-42 Feed Chute Pinch Roll Turn

-43 Feed Chute Tray Stop



-44 Feed Bracket Clamp

-45 02N6717 Lift Control Photo Sensor (same as 6-13)

-96 02N7015 Connector And Harness Kit (includes 6-39, 6-40)

-97 02N7964 Actuator And Support Kit (includes 6-11, 6-12)

-98 02N6724 Feed Asm (includes 6-01 to 6-45)


Pick And Retard Roll Kit (includes 5-08, 2 x 6-26)


Assembly 7: Aux Tray Chute

99 (with9,10)



7-01 02N6726 Aux Tray Asm (includes 7-02 to 7-31)

-02 Aux Pick Roll Asm (includes 7-03 to 7-06, 7-28)

-03 Aux Pick Roll Shaft

-04 Aux Pick Roll Right Cam

-05 Aux Pick Roll Core

-06 02N6727 Aux Pick Roll

-07 Bearing

-08 Aux Tray Bottom Asm (includes 7-11, 7-12)

-11 Aux Tray Bottom


Aux No Paper Actuator

-13 Aux Tray Bottom Spring

-14 Clip Bearing


Aux Retard Pad Asm


Aux No Paper Photo Sensor (same as 6-13)

-20 Aux Tray Ground Plate

-21 Aux Tray Frame


Aux Pick Up Solenoid


Aux Pick Up Gear Spring




Aux Pick Up Gear

-26 Env Connector Plate


Env Connector - Female

-28 Aux Pick Roll Left Cam


Harness (J45 - J451)

-30 Env Connector Asm (includes 7-26, 7-27)

-99 02N6736 Aux Pick Up Pad Asm (includes 7-09, 7-10)


Assembly 8: P/H Assembly

99 (with1~3,32,33)



8-01 Toner Sensor

-02 Toner Sensor Bracket

-03 Toner Sensor Spring

-04 02N6737 Paper Handling Asm (includes 8-02, 8-05 to 8-31, 8-36 to 8-39)

-05 Metal Registration Roll

-06 Front Registration Chute


Rubber Registration Roll

-08 Rear Registration Chute

-09 Upper Registration Chute Bottom Ground Spring

-10 02N6739 Registration Actuator

-11 02N6740 Registration Actuator Spring

-12 02N6717 Registration Sensor (same as 6-13)

-13 Left Metal Roll Bearing

-14 02N6742 Right Registration Roll Spring


Metal Registration Roll Gear


Rubber Registration Roll Gear

-17 Right Rubber Roll Bearing

-18 Left Rubber Roll Bearing

-19 02N6745 Registration Clutch - Electric

-20 Upper Registration Chute



-21 Upper Registration Chute Right Ground Spring

-22 Upper Registration Chute Center Ground Spring

-23 Grounding Screw

-24 Upper Registration Chute Left Ground Spring

-25 Upper Registration Chute Grounding Resistor

-26 Center Registration Chute

-27 Lower Registration Chute


Harness (J43 - J432, J433)

-29 Chute Torsion Spring

-30 Rear Registration Chute Handle

-31 Right Metal Roll Bearing

-32 Harness (J42 - J421)

-33 Toner Sensor Cushion

-34 02N6748 Aux Drive Gear Shaft

-35 02N6749 Aux Drive Gear

-36 02N8366 Left Registration Roll Spring

-37 Inlet Label

-38 Upper Registration Chute Clamp

-39 Rear Registration Chute Cap

-99 02N6750 Toner Sensor Asm (includes 8-01 to 8-03, 8-32, 8-33)


Assembly 9: Chute Transfer and Fuser

98 (with2,7)



9-01 BTR Asm (includes 9-02 to 9-26, 9-13)

-02 02N6751 Bias Transfer Roll

-03 02N6752 BTR Support Asm (includes 9-04 to 9-06, 9-13)

-04 BTR Support Bearing

-05 BTR Support Right Bearing Spring

-06 BTR Support Base


Fuser Asm 120 v (Customer Replaceable Unit)

02N8579 (notstocked)

Fuser Asm 230 v (Customer Replaceable Unit)

-10 Dts Wire

-11 Tr Wire


Harness (J27, J11, J262-J271) (120 v)

-13 BTR Support Left Bearing Spring

-14 BTR Lift

-98 Usage Kit 120V (includes 9-02, 9-07, 3 x 6-26)

Usage Kit 230V (includes 9-02, 9-07, 3 x 6-26)


Assembly 10: Exit

26

99 (with1~17,19~24)

98 (with6 (6x))



10-01 02N6755 Exit Static Eliminator

-02 02N6756 Full Stack Actuator

-03 Offset Exit Gate

-04 Offset Exit Gate Spring

-05 Exit Gear - 17

-06 Bearing

-07 02N6758 Exit Roll 1

-08 Outside Exit Pinch Roll

-09 Inside Exit Pinch Roll

-10 Top Exit Pinch Roll Spring

-11 02N6759 Exit Roll 2

-12 Small Exit Pinch Roll (same as 3-11)

-13 Middle Exit Pinch Roll Spring

-14 Lower Exit Pinch Roll Spring (same as 3-10)

-15 Exit Chute

-16 02N6717 Full Stack Photo Sensor (same as 6-13)



-18 Rear Interlock Switch Cover

-19 Exit Gear - 23

-20 Exit Gear - 33

-21 02N6762 Exit Motor



-22 Exit Gear - 17/47

-23 Exit Gear - 32

-24 Exit Chute Ground Spring

-25 Bearing

-26 02N6758 Exit Roll 1 (same as 10-07)

-98 02N7032 Bearing Kit (includes 6 x 10-06)

-99 02N6763 Exit Asm (includes 10-01 to 10-17, 10-19 to 10-24)


Assembly 11: Drive and Xerographics

99 (with2,5,6)



11-01 Toner Cartridge (customer replaceable unit - supply)

-02 Harness (J25 - J251)

-03 Toner Cartridge Top Guide Label

-04 02N6764 Toner Cartridge Top Guide

-05 Toner Cartridge Key Sensor Spring

-06 Toner Cartridge Key Sensor


Harness (J21 - J211, J212, J213)

-09 02N6767 ROS Asm (Laser)

-10 Toner Cartridge Right Guide Asm (includes 11-11, 11-12)

-11 Toner Cartridge Right Guide

-12 Toner Cartridge Right Guide Clip

-13 02N6768 Gear Drive Asm

-14 02N6769 Main Motor

-15 Toner Cartridge Right Guide Arm A

-16 Toner Cartridge Right Guide Spring A

-17 Toner Cartridge Right Guide Arm B

-18 Toner Cartridge Right Guide Spring B

-99 02N6770 Toner Cartridge Key Sensor (includes 11-02, 11-05, 11-06)


Assembly 12: Frame and Size Sensor

99 (with14~18)



12-01 PCB Cover Plate

-02 Harness Clamp

-03 Top Harness Clamp

-04 Square Harness Clamp

-05 Controller Front Frame

-06 Controller Lower Frame

-07 02N6771 Fan Motor

-08 Fan Duct

-09 Protective Harness Clamp

-10 Ac Harness Clamp

-11 MCU PCB Back Insulator

-12 Left Handle Plate


Harness (J33 - J331) (same as 14-13)

-14 Paper Size Cam (same as 14-10)

-15 Paper Size Cam Switch (same as 14-11)

-16 Paper Size Front Cover (same as 14-12)

-19 02N6773 Paper Size PCB



-21 Paper Size Housing (same as 14-06)

-22 Earth Spring



-99 02N6775 Paper Size Sensor Asm (includes 12-14 to 12-18)


Assembly 13: Electrical

23



13-01 02N6776 (notstocked)

Harness J282-J9, J288-J9

-02 01P4807 Controller PCB

-03 Controller Back Panel



-06 Power Cord

-07 02N6779 Rear Cover Interlock Switch

-08 Harness (AC - J85)


Harness (J34 - P341)



-11 02N6782 Interface PCB

-12 02N6783 Front Cover Interlock Switch

-13 02N6784 MCU PCB

-14 02N6785 5 V DC PCB



-17 02N6787 LVPS 120V

02N7027 LVPS 230V

-18 63H2286 Main Power Switch

-19 02N6788 Harness (J26 - J261)



-20 02N6789 HVPS

-21 HVPS Housing

-23 Harness (J1-J101)


Assembly 14: Optional Paper Drawer

Same as 15-01

Same as 4-01

99 (with8~12)



14-01 38L1395 Option Paper Drawer (includes 14-02 to 14-22)

-02 Option Gear Bracket

-03 02N6791 Option Top Gear

-04 Option Top Front Plate


Option Harness (J52 - J521)

-06 Option Paper Size Sensor Housing (same as 12-21)

-07 02N6793 Option Paper Size PCB

-10 Option Paper Size Cam (same as 12-14)

-11 Option Paper Size Cam Switch (same as 12-15)

-12 Option Paper Size Front Cover (same as 12-16)


Option Harness (J53 - J531) (same as 12-13)

-14 Option Clamp

-15 Option Frame

-16 02N6795 Option Right Cover

-17 Option Feed Asm (same as 15-01)

-18 550-Sheet Tray Asm (same as 4-01)

-19 Option Left Cover

-20 02N8375 Option Securing Screw

-21 Option Earth Spring

-22 Option Tray Stop



-23 Option Securing Screw Kit (includes 3 x 14-20)

-99 02N7007 Option Paper Size Sensor Asm (includes 14-08 to 14-12)


Assembly 15: Optional Tray 2

Same as 14-17

45



15-01 02N6798 Option Feed Asm (includes 15-02 to 15-44)

-02 02N6799 Option Pick Roll Asm (includes 15-03)

-03 Option Feed Roll Clutch

-04 Option Feed Roll Spring

-05 Option Chute Spring


Option No Paper Actuator (same as 6-06)

-07 Option No Paper Actuator Support

-08 Option Feed Frame

-09 Option Feed Clamp

-10 Option Latch Spring

-11 Option Low Paper Actuator

-12 Option Low Paper Actuator Support

-13 02N6717 Option Lift Control Photo Sensor (same as 6-13)


Option Sensor Cable (same as 6-14)

-15 Option Feed Position Plate

-17 Option Chute Pinch Roll

-18 Option Cover

-19 02N6719 Option Pick Roll Asm (includes 15-20 to 15-29)

-20 Option Pick Roll Shaft

-21 Bearing



-22 Option Pick Roll Support

-23 Option Pick Roll Clutch

-24 Option Pick Roll Clutch Support

-25 Option Pick Roll Clutch Interlock

-26 Option Pick Roll

-27 Option Pick Gear 25T

-28 Option Pick Gear 31T

-29 Option Pick Roll Support Spring

-30 Option Gear 4

-31 Option Gear 2

-32 Option Gear Cover Support

-33 Option Gear Cover

-34 Option Gear 3

-35 Option Gear 1

-36 02N6720 Option Feed PCB (same as 6-36)

-37 02N6721 Option Pick Clutch - Electric (same as 6-37)

-38 Bearing

-39 Option Socket Cable (same as 6-39)

-40 Option Socket (same as 6-40)

-41 Option Chute Pinch Roll Support

-42 Option Chute Pinch Roll Turn

-43 Option Chute Tray Stop



-44 Option Feed Bracket Clamp

-45 02N6717 Option Lift Control Photo Sensor (same as 6-13)


Assembly 16: Envelope Feeder

Same as 17-01

99 with (3~8)



16-01 38L1397 Env Tray Asm (includes 16-02 to 16-30)


Env Top Cover

-03 Env Retard Spring

-04 Env Retard Support

-05 Env Clutch - Torque 29

-06 Env Retard Shaft (includes 16-07)

-07 Env Retard Roll

-08 Bearing

-11 Env Arm Weight

-12 Env Lower Arm Weight

-13 Env Paper Width Left Guide

-14 Env Paper Width Right Guide

-16 Env Feed Asm (same as 17-01)

-17 Env Pinion Gear

-19 Env Bottom Cover

-20 Env Tray Extension

-22 Harness (J412 - J417)


Env Exit Photo Sensor

-24 Env Weight Cover

-26 Env Top Cover Chute



-27 Env Pinch Spring

-28 Env Pinch Cap

-29 Env Pinch Shaft

-30 Env Pinch Roll


Env Retard Roll Asm (includes 16-03 to 16-08)


Assembly 17: Envelope Feeder 2

Same as 16-16



17-01 Env Feed Asm (includes 17-02 to 17-34)

-02 Env Gear Cover

-03 Env Gear 29

-04 Env Drive Gear 21

-05 Env Gear 23

-06 Env Clutch - Torque 25

-07 Bearing

-08 Env Idler Gear

-09 Env Clutch - One Way 26

-10 Bearing

-11 Env Clutch - Electric

-12 Env Shaft Clutch - Electric


Env Clutch - One Way 26A

-15 Env Roll Shaft (includes 17-16)

-16 Env Transfer Roll

-17 Env Bottom Roll

-18 Env Pinch Roll (same as 16-21)

-19 Env Feed Belt

-20 Env Frame


Env No-Paper Actuator




Env No Paper Photo Sensor (same as 6-13)

-23 Env Roll Shaft 2

-25 Env Roll Shaft 3 (includes 17-26)

-26 Env Lower Roll

-30 Env Connector - Male

-31 Harness (J411 - J418)

-32 Harness (J413 - J416)

-33 Env PCB

-34 Harness (J414 - J415)


Assembly 18: Duplex 1



18-01 38L1394 Duplex Asm (includes 18-02 to 18-06)

-02 Duplex Upper Guide

-03 Duplex Connector Asm


Duplex Top Cover

-05 Duplex Motor Cover

-06 Duplex Sub Asm (same as 19-01)


Assembly 19: Duplex 2

Same as 18-06



19-01 Duplex Sub Asm (includes 19-02 to 19-19)Note: This part is not stocked. In its place, order 18-01, Duplex Asm, part number 38L1394.


Duplex Roll


Duplex Roll Retaining Clip

-04 Duplex Gear 17/Pulley

-05 Duplex Roll Bearing

-06 Duplex Gear 18

-07 Duplex Gear 17/39


Duplex Motor


Duplex Drive Belt

-10 Duplex Frame

-11 Duplex Latch

-12 Duplex Latch Spring

-13 Harness (J360 - J361)

-14 02N6717 Duplex Face-up Photo Sensor (same as 6-13)


Duplex PCB

-17 Duplex Bottom Cover


Duplex Paper Photo Sensor



-19 Duplex Label


Assembly 20: Offset Output Bin 1

Same as 21-01



20-01 38L1398 Offset Asm (includes 20-02 to 20-17)

-02 02N6826 Offset Exit Asm

-03 Offset Tray Spring


Offset Exit Bin

-06 02N6828 Offset Paper Weight


Offset Rear Cover


Offset Top Cover

-12 Offset Inner Asm (same as 21-01)

-13 Offset Top Cover Hook

-14 Offset Lower Cover

-15 Offset Rear Cover Spring Support

-16 Offset Rear Cover Left Spring

-17 Offset Rear Cover Right Spring


Assembly 21: Offset Output Bin 2

Same as 20-12



21-01 02N6831 (notstocked)Note: Order20-01, OffsetAsm, partnumber38L1398

Offset Inner Asm (includes 21-02 to 21-45)Note: This part is not stocked. In its place, order 20-01, Offset Asm, part number 38L1398.

-02 Harness (J21 - P202)

-03 Offset PCB Support


Offset PCB

-05 Offset Ground Plate


Offset Drive Motor

-07 Offset Exit Gear 20

-08 Bearing

-09 Offset Gear 27

-10 Offset Gear 26

-11 Offset Gear 47W

-12 Offset Exit Gear

-13 Offset Eliminator

-14 Offset Frame


Offset Direction Solenoid




Offset Direction Solenoid Lever

-17 Offset Direction Solenoid Pin


Offset Exit Photo Sensor

-19 02N6837 Offset Full Stack Actuator

-20 02N6717 Offset Full Stack Photo Sensor (same as 6-13)

-21 Harness (J224 - J225, J226, J227, J228)

-22 Offset Mech Roll Asm (includes 21-23 to 21-26, 21-45)

-23 Offset Exit Roll

-24 Offset Exit Pinch Roll

-25 Bearing

-26 Offset Exit Guide

-27 Offset Mechanism Asm Support

-28 Offset Mechanism Shaft

-29 Offset Roll Shaft

-30 Offset Pinch Roll

-31 Offset Pinch Roll Spring


Offset Inner Chute Cover


Offset Mechanism Asm (includes 21-35 to 21-39)



-35 Offset Mechanism Motor

-36 Offset Mechanism Motor Cover

-37 02N6717 Offset Direction Home Sensor (same as 6-13)

-38 Offset Mechanism Lever

-39 Offset Mechanism Gear

-40 Offset Ferrite Core

-41 Offset Ground Wire

-43 Offset Full Stack Sensor Bracket

-44 Offset Harness Clamp

-45 Offset Exit Guide Spring


Parts Reference

550-Sheet Tray AsmPart Number : 38L1396Parts Catalog : 04-01 “Assembly 4: 550-Sheet Tray Asm 1” on page 521Locations :Removals/Adjustments : “550-Sheet Tray Asm” on page 325Diagnostics :

5 V DC PCBPart Number : 02N6785Parts Catalog : 13-14 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “5v DC PCB” on page 326Theory : p. 620Diagnostics :

Actuator And Support KitPart Number : NoneParts Catalog : 6-97 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneDiagnostics :


Aux Drive GearPart Number : 02N6749Parts Catalog : 8-35 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Aux Drive Gear Shaft and Aux Drive Gear” on page 327Diagnostics :

Aux Drive Gear ShaftPart Number : 02N6748Parts Catalog : 8-34 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Aux Drive Gear Shaft and Aux Drive Gear” on page 327Diagnostics :

Aux Pick RollPart Number : 02N6727Parts Catalog : 7-06 “Assembly 7: Aux Tray Chute” on page 530Locations : “Rollers” on page 314Removals/Adjustments : “Aux Pick Roll” on page 332Diagnostics :


Aux Pick Up Pad AsmPart Number : 02N6736Parts Catalog : 7-99 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “Aux Pick Up Pad Asm” on page 337Diagnostics :

Aux TrayPart Number : 02N6701Parts Catalog : 1-17 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : “Aux Tray” on page 341Diagnostics :

Aux Tray AsmPart Number : 02N6726Parts Catalog : 7-01 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “Aux Tray Asm” on page 342Diagnostics :


Aux Tray StopPart Number : 02N6700Parts Catalog : 1-16 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : NoneDiagnostics :

Bearing KitPart Number : NoneParts Catalog : 10-98 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :

Bias Transfer RollPart Number : 02N6751Parts Catalog : 9-02 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Bias Transfer Roll” on page 346Theory : p. 620Diagnostics :


BTR Support AsmPart Number : 02N6752Parts Catalog : 9-03 “Assembly 9: Chute Transfer and Fuser” on page 536Locations :Removals/Adjustments : “BTR Support Asm” on page 347Diagnostics :

Coax NICPart Number : 02N8370Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :

Compact FlashPart Number : 02N8761Parts Catalog :Locations :Removals/Adjustments :Diagnostics :


Controller CoverPart Number : 02N6692Parts Catalog : 1-02 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Controller Cover” on page 348Diagnostics :

Controller PCBPart Number : 01P4807Parts Catalog : 13-02 “Assembly 13: Electrical” on page 546Locations : “Controller” on page 309Removals/Adjustments : “Controller PCB” on page 349Theory : p. 620Diagnostics :

Duplex AsmPart Number : 38L1394Parts Catalog : 18-01 “Assembly 18: Duplex 1” on page 562Locations : “Optional Features” on page 312Removals/Adjustments : “Duplex Asm” on page 350Diagnostics :


Duplex Face-up Photo SensorPart Number : 02N6717Parts Catalog : 19-14 “Assembly 19: Duplex 2” on page 564Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Duplex Face Up Photo Sensor” on page 354Theory : p. 620Diagnostics : 1020: Sensor/Switch Text

Env Connector - FemalePart Number : 02N6734 (not stocked)Parts Catalog : 7-27 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “ENV Connector - Female” on page 366Diagnostics :

Env No-Paper ActuatorPart Number : 02N6814 /not stocked)Parts Catalog : 17-21 “Assembly 17: Envelope Feeder 2” on page 559Locations :Removals/Adjustments : “ENV No Paper Actuator” on page 370Diagnostics :


Env Tray AsmPart Number : 38L1397Parts Catalog : 16-01 “Assembly 16: Envelope Feeder” on page 556Locations : “Optional Features” on page 312Removals/Adjustments : “ENV Tray Asm” on page 376Diagnostics :

Ethernet NICPart Number : 02N8368Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :

Exit AsmPart Number : 02N6763Parts Catalog : 10-99 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Asm” on page 379Diagnostics :


Exit CoverPart Number : 02N6693Parts Catalog : 1-04 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Exit Cover” on page 380Diagnostics :

Exit MotorPart Number : 02N6762Parts Catalog : 10-21 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Motor” on page 381Theory : p. 620Diagnostics : 1130: Exit Motor CW

Exit Roll 1Part Number : 02N6758Parts Catalog : 10-25 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :


Exit Roll 3Part Number : 02N6758Parts Catalog : 10-07 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :

Exit Roll 2Part Number : 02N6759Parts Catalog : 10-11 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Bearing and Exit Roll 2” on page 345Diagnostics :

Exit Static EliminatorPart Number : 02N6755Parts Catalog : 10-01 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Static Eliminator” on page 384Diagnostics :


Fan MotorPart Number : 02N6771Parts Catalog : 12-07 “Assembly 12: Frame and Size Sensor” on page 543Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fan Motor” on page 386Diagnostics : 1120: Fan Motor High

Feed AsmPart Number : 02N6724Parts Catalog : 6-98 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “Feed Asm” on page 387Diagnostics :

Feed Chute Pinch Roll SupportPart Number : NoneParts Catalog : 6-41 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments :Diagnostics :


Feed PCBPart Number : 02N6720Parts Catalog : 6-36 “Assembly 6: Paper Feeder” on page 526Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Feed PCB” on page 389Theory : p. 620Diagnostics :

Feed Roll AsmPart Number : 02N6714Parts Catalog : 6-01 “Assembly 6: Paper Feeder” on page 526Locations : “Rollers” on page 314Removals/Adjustments : “Feed Roll Asm” on page 388Diagnostics :

Feed Roll ClutchPart Number : NoneParts Catalog : 6-02 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneTheory : p. 620Diagnostics : 1250: Tray Feed Clutches


Font FlashPart Number : 02N6434Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :

Front Cover AsmPart Number : 02N6698Parts Catalog : 1-09 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Front Cover Asm” on page 391Diagnostics :

Front Cover Interlock SwitchPart Number : 02N6783Parts Catalog : 13-12 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Front Cover Interlock Switch” on page 392Diagnostics : 1020: Sensor/Switch Text


Front Cover StopPart Number : 02N6699Parts Catalog : 1-14 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : NoneDiagnostics :

Front Left CoverPart Number : 02N6702Parts Catalog : 1-19 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Front Left Cover” on page 395Diagnostics :

Full Stack ActuatorPart Number : 02N6756Parts Catalog : 10-02 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Full Stack Actuator” on page 396Diagnostics :


Full Stack Photo SensorPart Number : 02N6717Parts Catalog : 10-16 “Assembly 10: Exit” on page 538Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Full Stack Photo Sensor” on page 397Theory : p. 620Diagnostics : 1020: Sensor/Switch Text

Fuser Asm 120 vPart Number : 02N6753 (not stocked)Parts Catalog : 09-07 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fuser Asm” on page 398Theory : p. 620Diagnostics :

Fuser Asm 230 vPart Number : 02N8579 (not stocked)Parts Catalog : 09-07 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fuser Asm” on page 398Theory : p. 620Diagnostics :


Fuser Stop KitPart Number : NoneParts Catalog : 2-98 “Assembly 2: Covers 2” on page 517Locations :Removals/Adjustments : NoneDiagnostics :

Gear Drive AsmPart Number : 02N6768Parts Catalog : 11-13 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Gear Drive Asm” on page 400Diagnostics :

Hard DrivePart Number : 38L1408Parts Catalog :Locations :Removals/Adjustments :Diagnostics :


Harness (AC - J285)Part Number : NoneParts Catalog : 13-08 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J1 - J101)Part Number : NoneParts Catalog : 13-22 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J21 - J211, J212, J213)Part Number : NoneParts Catalog : 11-07 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :


Harness (J22 - J223)Part Number : 02N6766 (not stocked)Parts Catalog : 11-08 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J23 - J231)Part Number : 02N6781 (not stocked)Parts Catalog : 13-10 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J25 - J251)Part Number : NoneParts Catalog : 11-02 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : “Toner Cartridge Key Sensor” on page 490Diagnostics :


Harness (J26 - J261)Part Number : 02N6788Parts Catalog : 13-19 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J27, J11, J262-J271)Part Number : 02N6754 (not stocked)Parts Catalog : 9-12 “Assembly 9: Chute Transfer and Fuser” on page 536Locations :Removals/Adjustments : “Harness (J27, J11, J262 - J271)” on page 401Diagnostics :

Harness (J28 - J281)Part Number : 02N6786 (not stocked)Parts Catalog : 13-15 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :


Harness (J282 - J9, J288 - J9)Part Number : 02N6776 (not stocked)Parts Catalog : 13-01 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J31 - J311)Part Number : 02N6761 (not stocked)Parts Catalog : 10-17 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J33 - J331)Part Number : 02N6772 (not stocked)Parts Catalog : 12-13 “Assembly 12: Frame and Size Sensor” on page 543Locations :Removals/Adjustments : NoneDiagnostics :


Harness (J34 - J341)Part Number : NoneParts Catalog : 11-09 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : “Harness (J34-P341)” on page 403Diagnostics :

Harness (J34 - P341)Part Number : 02N6780 (not stocked)Parts Catalog : 13-09 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Harness (J34-P341)” on page 403Diagnostics :

Harness (J35 - J351)Part Number : 02N6777 (not stocked)Parts Catalog : 13-04 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Harness (J35 - J351)” on page 404Diagnostics :


Harness (J4 - Operator Panel)Part Number : NoneParts Catalog : 11-07 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J42 - J421)Part Number : NoneParts Catalog : 8-32 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Toner Sensor Asm” on page 492Diagnostics :

Harness (J43 - J432, J433)Part Number : 02N6746 (not stocked)Parts Catalog : 8-28 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : NoneDiagnostics :


Harness (J45 - J451)Part Number : 02N6735 (not stocked)Parts Catalog : 7-29 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : NoneDiagnostics :

Harness (J51 - J511)Part Number : 02N6774 (not stocked)Parts Catalog : 12-20 “Assembly 12: Frame and Size Sensor” on page 543Locations :Removals/Adjustments : “Harness (J51 - J511)” on page 405Diagnostics :

Harness (J66 - J661, J662)Part Number : 02N6718 (not stocked)Parts Catalog : 6-14 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneDiagnostics :


HVPSPart Number : 02N6789Parts Catalog : 13-20 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “HVPS” on page 406Theory : p. 621Diagnostics :

IBM AFP/IPDS ModulePart Number : 02N6723Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :

Interface PCBPart Number : 02N6782Parts Catalog : 13-11 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Interface PCB” on page 407Theory : p. 621Diagnostics :


Left CoverPart Number : 02N6691Parts Catalog : 1-01 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Left Cover” on page 408Diagnostics :

Left Registration Roll SpringPart Number : 02N8366Parts Catalog : 8-36 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Left Registration Roll Spring” on page 410Diagnostics :

LVPS 120VPart Number : 02N6787Parts Catalog : 13-22 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “LVPS” on page 412Theory : p. 621Diagnostics :


LVPS 230VPart Number : 02N7027Parts Catalog : 13-17 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “LVPS” on page 412Diagnostics :

Main MotorPart Number : 02N6769Parts Catalog : 11-14 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Main Motor” on page 413Theory : p. 621Diagnostics :

Main Power SwitchPart Number : 63H2286Parts Catalog : 13-18 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Main Power Switch” on page 414Diagnostics :


MCU PCBPart Number : 02N6784Parts Catalog : 13-13 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “MCU PCB” on page 415Theory : p. 621Diagnostics :

Memory DIMMPart Numbers : 38L1405 (32MB), 38L1406 (64MB), 38L1407 (128MB)Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :

No Paper ActuatorPart Number : 02N6716 (not stocked)Parts Catalog : 6-06 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “No Paper Actuator” on page 419Diagnostics :


Offset AsmPart Number : 38L1398Parts Catalog : 20-01 “Assembly 20: Offset Output Bin 1” on page 567Locations : “Optional Features” on page 312Removals/Adjustments : “Offset Asm” on page 420Diagnostics :

Offset Direction Home SensorPart Number : 02N6717Parts Catalog : 21-37 “Assembly 21: Offset Output Bin 2” on page 569Locations :Removals/Adjustments : “Offset Direction Home Sensor” on page 422Theory : p. 621Diagnostics :

Offset Exit AsmPart Number : 02N6826Parts Catalog : 20-02 “Assembly 20: Offset Output Bin 1” on page 567Locations :Removals/Adjustments : “Offset Exit Bin Asm” on page 425Diagnostics :


Offset Full Stack ActuatorPart Number : 02N6837Parts Catalog : 21-19 “Assembly 21: Offset Output Bin 2” on page 569Locations :Removals/Adjustments : “Offset Full Stack Actuator” on page 427Diagnostics :

Offset Full Stack Photo SensorPart Number : 02N6717Parts Catalog : 21-20 “Assembly 21: Offset Output Bin 2” on page 569Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Offset Full Stack Photo Sensor” on page 428Theory : p. 621Diagnostics :

Offset Paper WeightPart Number : 02N6828Parts Catalog : 20-06 “Assembly 20: Offset Output Bin 1” on page 567Locations :Removals/Adjustments : “Offset Paper Weight” on page 433Diagnostics :


Operator PanelPart Number : 02N6695Parts Catalog : 1-06 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : “Operator Panel” on page 437Diagnostics :

Option Feed AsmPart Number : 02N6798Parts Catalog : 15-01 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : “Option Feed Asm” on page 439Diagnostics :

Option Feed PCBPart Number : 02N6720Parts Catalog : 15-36 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : NoneTheory : p. 621Diagnostics :


Option Pick Roll AsmPart Number : 02N6799Parts Catalog : 15-02 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : “Option Pick Roll Asm” on page 457Diagnostics :

Option Left CoverPart Number : NoneParts Catalog : 14-19 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :

Option Paper DrawerPart Number : 38L1395Parts Catalog : 14-01 “Assembly 14: Optional Paper Drawer” on page 549Locations : “Optional Features” on page 312Removals/Adjustments : NoneDiagnostics :


Option Paper Size PCBPart Number : 02N6793Parts Catalog : 14-07 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : “Option Paper Size PCB” on page 452Theory : p. 621Diagnostics :

Option Paper Size Sensor AsmPart Number : 02N6775Parts Catalog : 14-99 “Assembly 14: Optional Paper Drawer” on page 549Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Option Paper Size Sensor Asm” on page 453Diagnostics :

Option Pick Clutch - ElectricPart Number : 02N6721Parts Catalog : 15-37 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : NoneDiagnostics :


Option Pick Roll AsmPart Number : 02N6719Parts Catalog : 15-19 “Assembly 15: Optional Tray 2” on page 552Locations : “Rollers” on page 314Removals/Adjustments : NoneDiagnostics :

Option Right CoverPart Number : 02N6795Parts Catalog : 14-16 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :

Option Top GearPart Number : 02N6791Parts Catalog : 14-03 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :


Paper Handling AsmPart Number : 02N6737Parts Catalog : 8-04 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Paper Handling Asm” on page 462Diagnostics :

Paper Low Photo SensorPart Number : 02N6717Parts Catalog : 6-13 “Assembly 6: Paper Feeder” on page 526Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Paper Low Photo Sensor” on page 463Theory : p. 622Diagnostics :

Paper Size PCBPart Number : 02N6773Parts Catalog : 12-19 “Assembly 12: Frame and Size Sensor” on page 543Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Paper Sizing PCB” on page 466Theory : p. 622Diagnostics :


Paper Size Sensor AsmPart Number : 02N6775Parts Catalog : 12-99 “Assembly 12: Frame and Size Sensor” on page 543Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Paper Size Housing Asm” on page 465Diagnostics :

Pick Clutch - ElectricPart Number : 02N6721Parts Catalog : 6-37 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “Pick Clutch - Electric” on page 468Diagnostics :

Pick Roll AsmPart Number : 02N6719Parts Catalog : 6-19 “Assembly 6: Paper Feeder” on page 526Locations : “Rollers” on page 314Removals/Adjustments : “Pick Roll Asm” on page 471Diagnostics :


Rear Cover Asm (With Face-Up Bin)Part Number : 38L1399Parts Catalog : 3-01 “Assembly 3: Covers 3” on page 519Locations : “Covers” on page 310Removals/Adjustments : “Rear Cover Asm” on page 473Diagnostics :

Rear Cover Asm (Without Face-Up Bin)Part Number : 02N6705Parts Catalog : 2-99 “Assembly 2: Covers 2” on page 517Locations : “Covers” on page 310Removals/Adjustments : “Rear Cover Asm” on page 473Diagnostics :

Rear Cover Interlock SwitchPart Number : 02N6779Parts Catalog : 13-07 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Rear Cover Interlock Switch” on page 474Diagnostics :


Rear Cover StopPart Number : 02N6704Parts Catalog : 2-10 “Assembly 2: Covers 2” on page 517, 3-16 “Assembly 3: Covers 3” on page 519Locations :Removals/Adjustments : “Rear Cover Stop” on page 476Diagnostics :

Registration ActuatorPart Number : 02N6739Parts Catalog : 8-10 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Actuator” on page 479Diagnostics :

Registration Actuator SpringPart Number : 02N6740Parts Catalog : 8-11 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Actuator Spring” on page 480Diagnostics :


Registration Clutch - ElectricPart Number : 02N6745Parts Catalog : 8-19 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Clutch - Electric” on page 481Theory : p. 622Diagnostics :

Registration SensorPart Number : 02N6717Parts Catalog : 8-12 “Assembly 8: P/H Assembly” on page 533Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Registration Sensor” on page 482Theory : p. 622Diagnostics :

Right CoverPart Number : 02N6697Parts Catalog : 1-08 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Right Cover” on page 483Diagnostics :


Right Registration Roll SpringPart Number : 02N6742Parts Catalog : 8-14 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Left Registration Roll Spring” on page 410Diagnostics :

ROS Asm (Laser)Part Number : 02N6767Parts Catalog : 11-09 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “ROS Asm (Laser)” on page 485Theory : p. 622Diagnostics :

Token Ring NICPart Number : 02N8367Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :


Toner CartridgePart Number : NoneParts Catalog : 11-01 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments :Theory : p. 622Diagnostics :

Toner Cartridge Key SensorPart Number : 02N6770Parts Catalog : 11-99 “Assembly 11: Drive and Xerographics” on page 541Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Toner Cartridge Key Sensor” on page 490Theory : p. 622Diagnostics :

Toner Cartridge Top GuidePart Number : 02N6764Parts Catalog : 11-04 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :


Toner Sensor AsmPart Number : 02N6750Parts Catalog : 8-99 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Toner Sensor Asm” on page 492Theory : p. 622Diagnostics :

Top CoverPart Number : 02N6694Parts Catalog : 1-06 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Top Cover” on page 493Diagnostics :

Tray Lift MotorPart Number : 02N6712Parts Catalog : 5-22 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Lift Motor Asm” on page 496Theory : p. 622Diagnostics :


Tray Retard Clutch - FrictionPart Number : 02N6710Parts Catalog : 5-07 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Retard Clutch - Friction” on page 498Diagnostics :

Tray Retard SpringPart Number : 02N6711Parts Catalog : 5-10 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Retard Spring” on page 502Diagnostics :

Twinax NICPart Number : 02N8369Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :


Chapter 7. Preventive Maintenance

Periodically Replaced Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615

Preventive maintenance for this printer is the responsibility of the customer. It requires the customer to periodicallyreplace supplies (parts). Although the customer may choose to have a service representative perform thepreventive maintenance (parts replacement) on a “per-call” basis, the customer is still responsible for purchasingthe supplies.

Periodically Replaced SuppliesThe following table lists the supplies and expected lives of customer-replaceable parts. The customer should referto the User’s Guide for replacement of these parts.

Supply Name Customer Part Number Expected Life (approximate)

Toner Cartridge 38L1410 15,000 images

Usage Kit (100-140 Volt) 38L1411 200,000 images

Usage Kit (230 Volt) 38L1412 200,000 images

The initial toner cartridge can print approximately 8,000 pages of Letter-size paper, containing text or graphics thatcover 5% of the page. This yield was established with the default DENSITY setting and QUALITY set to NORMAL(Config Menu). Toner cartridges after the first can print approximately 15,000 pages in the same conditions. TheQUALITY=ECONO setting can increase the life of the toner cartridge by up to 20% to 30%. This yield increasewas established with a toner coverage of 5% on letter-size paper, default DENSITY setting, QUALITY=ECONOsetting, and an average of 3 to 4 pages per print job. (Note that the print driver settings will override all othersettings.)

Note: The actual page yield is affected by the environment, the type of print media, the orientation of the printmedia, the percentage of text and graphics, the complexity of the graphics, and other factors, so actualresults can vary.


Appendix A. Installation

The Infoprint 21 is a customer install and setup product. The customer may, however, choose to have a servicerepresentative perform the installation on a charge-per-call basis or under the terms and conditions of a specialbid.


Appendix B. Drivers, Technical Support, and Warranty Information

Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Dealer Warranty Claim Center (DWCC), U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618

Maintenance (Service) Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619

Driver InformationFind the latest level printer drivers at the IBM Printing Systems website at:www.printers.ibm.com


Technical SupportIBM support for this printer is available at no charge when covered by the IBM one-year warranty, or an IBMmaintenance agreement.

If the service procedures that you choose do not solve the problem, return to “MAP 010: Start MAP” on page 44and define the problem again or callv 1-800-358-6661 for technical support in the U.S.A. and Canadav Outside the U.S.A. and Canada, call your country customer service center

Warranty Information

Warranty PeriodIBM warrants this printer for 1 year (12 months).

Warranty ServiceOn-site warranty service can be arranged through IBM. In the U.S.A. and Canada, call 1-800-358-6661.

Dealer Warranty Claim Center (DWCC), U.S.A. onlyTo order warranty parts or to request warranty claim reimbursements through the Dealer Warranty Claim Center,call 1-800-388-7080.

Appendix B. Drivers, Technical Support, and Warranty Information 618

Maintenance (Service) AgreementContact your IBM representative or your local IBM Branch Office for information. In the U.S.A. and Canada youcan call 1-800-358-6661.

Appendix B. Drivers, Technical Support, and Warranty Information 619

Appendix C. Parts Theory5 V DC PCB

The 5v DC PCB supplies 5v DC to the Controller PCB. This 5v is used by the controller PCI modules suchas the Hard Drive and NICs.

Bias Transfer RollThe Bias Transfer Roll is used in the EP process to transfer toner from the drum in the Toner Cartridge on tothe paper.

Controller PCBThe Controller PCB generates the raw page image data and handles communication with the printercontroller and the NIC cards. This PCB also controls the Operator Panel.

Duplex Face-up Photo SensorThe Duplex Face-Up Photo Sensor detects when the Face-Up Bin is open. If the face-up bin is open, duplexcapability is disabled.

Exit MotorThe Exit Motor drives the exit gears and rollers. This motor is also used during duplex printing to move thepaper into the Duplex Asm.

Feed PCBThe Feed PCB controls the pick and feed clutches and the Tray Lift Motor for the tray. The No Paper PhotoSensor is also installed on the Feed PCB.

Feed Roll ClutchThe Feed Roll Clutch operates the feed rolls for each tray, transporting the paper to the registration roller.

Full Stack Photo SensorThe Full Stack Photo Sensor detects when the Main Bin is full of paper. The MCU PCB posts an error code031 after this sensor is continuously activated for 100 printed pages.

Fuser AsmThe Fuser Asm is a customer-replaceable unit that “fuses” or fixes the toner to the paper using heat andpressure.


HVPSThe High Voltage Power Supply supplies high DC and AC voltages to the Toner Cartridge, Bias TransferRoll, and Fuser Asm. These voltages are needed for the EP process.

Interface PCBThe Interface PCB passes signals from the MCU PCB to the Paper Handling Asm, the Envelope Asm andthe Aux Tray.

LVPSThe Low Voltage Power Sopply supplies all signal and motor DC voltages needed by the printer and MCUPCB. The LVPS also supplies 3.3v DC to the Controller PCB that is used for the controller logic.

Main MotorThe Main Motor drives the Gear Drive Asm and associated rollers to move paper from the pick rollers ineach tray to the Fuser Asm.

MCU PCBThe MCU PCB controls all printer functions, including all motors, clutches and sensors. This card is alsoresponsible for posting error codes to the Controller PCB for display on the Operator Panel.

Offset Direction Home SensorThe Offset Direction Home Sensor detects where the Offsetting Mechanism in the Offset Asm is currentlylocated.

Offset Full Stack Photo SensorThe Offset Full Stack Photo Sensor detects when the Offset Bin is full of paper. The MCU PCB posts anerror code 035 after this sensor is continuously activated for 100 printed pages.

Option Feed PCBThe Option Feed PCB controls the pick and feed clutches for the Option Drawer as well as operating theOption Tray Lift Motor. The No Paper Photo Sensor is also included on this PCB.

Option Paper Size PCBThe Option Paper Size PCB passes signals between the Paper Size PCB, the Option Feed PCB, and theTray 3 Option Paper Size PCB, if installed. The Paper Size Switches that are used to detect the currentpaper size in the tray are also installed on this PCB.

Appendix C. Parts Theory 621

Paper Low Photo SensorThe Paper Low Photo Sensor detects when the tray paper supply is less than 50 standard sheets.

Paper Size PCBThe Paper Size PCB passes signals between the MCU PCB, the Feed PCB and Trays 2 and 3, if installed.The Paper Size Switches that are used to detect the current paper size in the tray are also installed on thisPCB.

Registration Clutch - ElectricThe Registration Clutch - Electric activates the registration rollers after the Registration sensor detects thepaper.

Registration SensorThe Registration Sensor detects when the paper has successfully entered the registration rollers from thetray.

ROS Asm (Laser)The ROS Asm contains a laser that produces a light to expose areas on the drum inside the TonerCartridge. The drum then attracts toner onto the areas the laser has exposed, which is later transferred tothe paper.

Toner CartridgeThe Toner Cartridge is a customer-replaceable unit that contains the toner and drum.

Toner Cartridge Key SensorThe Toner Cartridge Key Sensor detects if an IBM Toner Cartridge is installed. If a non-IBM Toner Cartridgeis installed, the sensor will not recognize the cartridge.

Toner Sensor AsmThe Toner Sensor is a magnetic sensor used to detect a low toner condition in the Toner Cartridge. Once alow toner condition is detected, the Toner Cartridge should be replaced or print quality will severly degrade(lighten).

Tray Lift MotorThe Tray Lift Motor is used to raise the tray’s paper supply until contact is made with the pick rollers.

Appendix C. Parts Theory 622

IBMR

Printed in the United States of Americaon recycled paper containing 10%recovered post-consumer fiber.

G544-5702-00

4322 service manuals

Documents