infoprint 20 svc guide 2
TRANSCRIPT
IBM InfoPrint 20
Service Guide
Document Number: G544-5514-01
IBM
NoteBefore using this information and the product it supports, be sure to read the generalinformation in “Notices” on page 5.
Second Edition (August 1998)
This edition applies to Release 2.0 of the IBM InfoPrint 20 Service Guide, G544-5514-01.
The following paragraph does not apply to any country where such provisions are inconsistent with local law.
INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OFANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO THE IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or impliedwarranties in certain transactions; therefore, this statement may not apply to you.
Order publications through your IBM representative, your IBM Printing Systems Company printing specialist, or the IBM branchoffice serving your locality. Publications are not stocked at the address given below.
IBM Printing Systems Company home page:http://www.printers.ibm.com
IBM and the IBM Printing Systems Company welcome your comments. Either fax your comments to 1-303-924-6873, e-mailthem to [email protected], or mail them to:
Department H7FE, Building 003G
The IBM Printing Systems Company
Information Development
P.O. Box 1900
Boulder, CO 80301-9191, U.S.A.
When you send information to IBM, you grant IBM a non-exclusive right to use or distribute the information in any way it believesappropriate without incurring any obligation to you. Copyright International Business Machines Corporation 1998. All rightsreserved. Note to U.S. Government Users—Documentation related to restricted rights—use, duplication or disclosure is subjectto restrictions set forth in GSA ADP Schedule Contract with IBM Corporation.
© Copyright International Business Machines Corporation 1998. All rights reserved.Note to U.S. Government Users — Documentation related to restricted rights — Use, duplication or disclosure is subject torestrictions set forth in GSA ADP Schedule Contract with IBM Corp.
Master Table of Contents“Notices” on page 5
“About This Book” on page 23
“Chapter 1. Getting Started” on page 25
“Chapter 2. Diagnosing Problems” on page 37
“Chapter 3. Diagnostic Tools” on page 247
“Chapter 4. Circuit Diagrams” on page 307
“Chapter 5. Locations” on page 360
“Chapter 6. Removal Procedures, Adjustments” on page 394
“Chapter 7. Preventive Maintenance and Usage Kit” on page 543
“Chapter 8. Parts Catalog” on page 544
“Appendix A. Features” on page 589
“Appendix B. Supplies” on page 591
“Appendix C. Media Specifications” on page 593
“Appendix D. Technical Support” on page 602
“Appendix E. Duplex Unit Option” on page 604
“Appendix F. Envelope Tray Option” on page 658
© Copyright IBM Corp. 1998 3
“Appendix G. 500-Sheet Paper Tray Option” on page 661
“Appendix H. 2000-Sheet Input Drawer Option” on page 703
“Index” on page 788
Master Table of Contents 4
NoticesReferences in this publication to IBM products, programs or services do not imply that IBM intends to makethese available in all countries in which IBM operates. Any reference to an IBM licensed product, program, orservice is not intended to state or imply that only IBM’s product, program, or service may be used. Anyfunctionally equivalent product, program, or service that does not infringe any of IBM’s intellectual propertyrights may be used instead of the IBM product. Evaluation and verification of operation in conjunction withother products, except those 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 useof specific data. The results that may be obtained in other operating environments may vary significantly.Users of this document should verify the applicable data in their specific environment. Therefore, such datadoes not constitute a performance guarantee or warranty.
IBM may have patents or pending patent applications covering subject matter in this document. The furnishingof this document does not give you any license to these patents. You can send license inquiries, in writing, tothe IBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States,06904.
© Copyright IBM Corp. 1998 5
Safety NoticesThere are three levels of safety notices: DANGER, CAUTION, and Attention.
Danger NoticesThe word Danger indicates the presence of a hazard that has the potential of causing death or seriouspersonal injury.
Danger notices are numbered <1-10>, <1-11>, and so forth where they appear in the text of this manual. Usethe notice number to locate the national language translation of that notice in the IBM InfoPrint 20: SafetyInstructions.
Example danger notice:
Notices 6
Caution NoticesThe word Caution indicates the presence of a hazard that has the potential of causing moderate or minorpersonal injury.
Caution notices are numbered <2-20>, <2-21>, and so forth where they appear in the text of this manual. Usethe notice number to locate the national language translation of that notice in the IBM InfoPrint 20: SafetyInstructions.
Example caution notice:
Notices 7
Safety Precautions
Disposal of Materials
Electrical SafetyThis printer is inspected and listed by recognized national testing laboratories, such as UnderwritersLaboratories, Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of aproduct by a national testing laboratory indicates that the product is designed and manufactured in accordancewith national requirements intended to minimize safety hazards. IBM equipment meets a very high standard ofsafety in design and manufacture. Remember, however, that this product operates under conditions of highelectrical potentials and heat generation, both of which are functionally necessary.
Because the paper and toner used in the printer can burn, take normal precautions to prevent fire. Theseprecautions include common-sense measures, such as keeping potentially combustible materials (for example,curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limiting unattended
Notices 8
operation, and having trained personnel available and assigned to the printer.
Notices 9
Laser SafetyThis printer complies with the performance standards set the by U.S. Food and Drug Administration for aClass 1 Laser Product. This means that the printer belongs to a class of laser products that does not producehazardous laser radiation in a customer access area. This classification was accomplished by providing thenecessary protective housing and scanning safeguards to ensure that laser radiation is inaccessible or withinClass 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. Noadjustments that affect laser operation or power are accessible to the operator. See the IBM InfoPrint 20:Safety Instructions for national language translations regarding laser safety.
Notices 10
Ozone SafetyAn infinitesimal amount of ozone gas (O3) is generated during corona discharge from the transfer chargeroller. The ozone gas is emitted only when the printer is operating.
This printer meets the ozone emission reference value set by Underwriters Laboratory (UL) at the time it isshipped from the factory.
Toner SafetyToner is a non-poisonous substance composer of minute, plastic components. If toner adheres to your skin orto your clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hotwater, the toner will gel and become difficult to remove.
As toner easily breaks down vinyl materials, avoid letting toner come into contact with vinyl.
Notices 11
Safety InspectionSee “Danger Notices” on page 6 and “Caution Notices” on page 7 for an explanation of these notices.
InstructionsPerform a safety inspection before performing any of the following tasks:v Accepting a machine for a service agreementv Providing per-call servicev Relocating a machinev Reviewing changes or attachments on any IBM machine that is leased, on service agreement, or on
per-call service
Correct unsafe conditions before you continue.
Possible safety hazards are:v 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.
Notices 12
Reference ItemsYou need the following items:v A copy of the machine EC historyv Electrical Safety for IBM Customer Engineers, S229-8124
Printer Safety Inspection1. Switch off printer power and unplug the power cord from the wall.2. Perform the “Power-Receptacle Safety-Check” on page 17.
3. Ensure that all cables are disconnected from the printer.4. Ensure that the correct power cord is used.5. Inspect the power cord for wear or damage.6. Ensure that the machine is steady.7. Remove all covers and access panels (see “Chapter 6. Removal Procedures, Adjustments” on page 394).
8. Inspect the covers and access panels for damage.9. Ensure that all warning labels are in place.
10. If you are placing this printer on a service contract with IBM, check for changes not made by IBM. If youfind changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBMbranch office. Complete the form and return it to the branch office.
11. Ensure that all ground connectors are correctly connected and tight (see Figure 1 on page 15 andFigure 2 on page 16.)
12. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. Thereading must not exceed 0.1 ohm.
13. Inspect all cables, connections, and plugs for worn or damaged wiring.
Notices 13
14. Check for signs of contamination, corrosion, smoke, or burning. If there are signs of smoke or burning,check the Maintenance Agreement Qualification (MAQ) form for the correct repair procedure.
15. Replace all covers and access panels.
The printer system diagram and ground locations are shown below. For a detailed description of the signals,see “Chapter 4. Circuit Diagrams” on page 307.
Notices 14
(CRU SENSOR ASSEMBLY)LD SWITCH 5VDC
INTERLOCKDETECTION
LOGIC
FUSERCONTROL
LOGIC
(FUSER COVER SWITCH)
(MCU PWB)
(ROS ASSEMBLY)
LD SCANNERMOTOR
(MAIN MOTOR)
(HVPS)
(FUSER ASSEMBLY)
HEATERASSEMBLY
AC
L
AC
N
(HEATER ROD)
THERMOSTAT THERMALFUSE
SG
SG
(LVPS ASSEMBLY)
FEED BACK
HEATERCONTROL
OUTPUTCONTROL
5VDCSUPPLY
5V
DC
FANCONTROL
24VDCSUPPLY
FUSE
POWERSWITCH
AC L
AC N
(FAN)
hc2m004F
(INTERLOCKSWITCH)
(INTERLOCKSWITCH)
SG
FG
FG
FG
SG
RTN
FAN ON
RT
NF
AN
FA
ST
FA
NA
LA
RM
24
VD
C
TEMPERATURESENSOR
ASSEMBLY
(LD ASSEMBLY) (SCANNER ASSEMBLY)
Figure 1. IBM InfoPrint 20 System Diagram and Ground Locations
Notices 15
Screw,Star Washer
Lug
Typical GND Detail
hc2m131F
Figure 2. Ground Connector Detail
Notices 16
Power-Receptacle Safety-Check
See Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and proceduresbefore performing any of the following tasks. (Electrical Safety for IBM Customer Engineers, S229-8124 maynot be 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. See the applicable table below for the permitted acvoltage range and record the voltage measured:v See Table 1 on page 18, “Nominal AC Line Voltages at Power Receptacle (110 V ac–120 V ac)”
v See Table 2 on page 18, “Nominal AC Line Voltages at Power Receptacle (220 V ac–240 V ac)”
v See Table 3 on page 19, “Nominal AC Line Voltages at Power Receptacle (220 V ac–240 V ac, 3 PhaseWye Connected)”
Notices 17
Do not continue until the voltages are in the correct range.Table 1. Nominal AC Line Voltages at Power Receptacle (110–120 Vac)
Nominal Line Voltages 100, 110, 120, and127 V ac
Recorded LineVoltages
Phase to Neutral50 Hz 90–119 V ac V ac
60 Hz 90–137 V ac V ac
Phase to Ground50 Hz 90–119 V ac V ac
60 Hz 90–137 V ac V ac
Ground to Neutral <1.0 V ac V ac
Table 2. Nominal AC Line Voltages at Power Receptacle (220 V ac–240V ac)
Nominal Line Voltages 200, 208, 220, 230,and 240 V ac
Recorded LineVoltages
Phase A to Ground 90–137 V ac V ac
Phase B to Ground 180–254 V ac V ac
Phase A to Phase B50 Hz 180–259 V ac V ac
60 Hz 180–254 V ac V ac
Notices 18
Table 3. Nominal AC Line Voltages at Power Receptacle (220 V ac–240V ac, 3 Phase Wye Connected)
Nominal Line Voltages 3-Phase WyeConnected 200, 208, 220, 230, and 240 V ac
Recorded LineVoltages
Phase to Neutral50 Hz 180–259 V ac V ac
60 Hz 180–254 V ac V ac
Phase to Ground50 Hz 180–259 V ac V ac
60 Hz 180–254 V ac V ac
Ground to Neutral <1.0 V ac V ac
Notices 19
Electrostatic Discharge (ESD) ProceduresAttention: If discharged into the circuitry of an integrated circuit, static electricity can damage the circuit.
Follow these procedures to prevent damage to ESD-sensitive components;1. Use the ESD Kit.
a. Turn off the printer before you put on the ESD wrist band.b. Connect the wrist band to an unpainted, frame-ground point of the printer.c. Remove the ESD wrist band when working on any part of the printer that has power turned on.d. Do not put the ESD mat near any electrical circuit that has power turned on. The internal resistance
(1 megaohm) in the ESD cable limits the current if it touches a high voltage.e. Do not put the ESD mat near a grounded surface. Ground the ESD mat only through the ESD cable.
The ESD cable supplies a high resistance to ground for your safety. If the ESD mat touches agrounded surface, the high resistance in the ESD cable is bypassed, which causes the ESD mat not towork as expected.
2. Keep an ESD-sensitive part in its original shipping container, usually a protective bag, until you are readyto install it.
3. Make the fewest possible movements to minimize static electricity.4. Touch the metal frame of the printer or the assembly to discharge static electricity in your body before
touching the ESD-sensitive part.5. Hold the ESD-sensitive part by its edges. Do not touch any components, pins, or connectors. If possible,
keep one hand on the frame while you are installing or removing an ESD-sensitive part.6. Do not place an ESD-sensitive part on anything that can provide a discharge path from your body through
the ESD-sensitive part. If you need to put down the ESD-sensitive part, first put it into the ESD protectivewrapper in which it was shipped.
7. Prevent other persons from touching ESD-sensitive parts.
Notices 20
8. Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working withconnectors.
9. Be careful when working with ESD-sensitive parts when the humidity is low. Low humidity increases staticelectricity.
Notices 21
TrademarksThe following terms are trademarks of the IBM Corporation in the United States or other countries or both:
AIXAIX/6000IBMInfoPrintOS/2Personal System/2PS/2RISC System/6000WIN-OS/2
The following terms are trademarks or registered trademarks of other companies:
Acrobat Adobe Systems, Inc.Adobe Adobe Systems, Inc.Adobe logo Adobe Systems, Inc.Apple Apple Computer, Inc.Apple logo Apple Computer‘, Inc.Ethernet Xerox CorporationMacintosh Apple Computer, Inc.Microsoft Microsoft Corp.Mylar E. I. du Pont de Nemours & Co., Inc.Novell Novell Inc.PostScript Adobe Systems, Inc.UNIX AT&T CorporationWindows Microsoft Corp.
© Copyright IBM Corp. 1998 22
About This BookThis book is designed to help you service the IBM InfoPrint 20. It describes how to:v Define and solve problems with the printerv Diagnose printer problemsv Service the printerv Locate printer componentsv Remove and replace printer componentsv Identify printer parts for repair and procurementv Diagnose and repair electrical problemsv Perform preventive and periodic maintenance
© Copyright IBM Corp. 1998 23
Related PublicationsTo obtain additional copies of this book or of any related publication, contact your IBM service representative,your authorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755 or 1-919-713-4055.
Document Number
These service documents must be ordered separately:
v IBM InfoPrint 20: Service CD-ROM. The Service CD-ROM includes the service guide for the IBMInfoPrint 20, as well as the customer documents that ship with the printer. These documents areviewable using Adobe Acrobat Reader, which is included on the CD-ROM.
GK2T-9265
v IBM InfoPrint 20: Service Guide (Hardcopy) G544-5514
These books are included with the printer:
v IBM InfoPrint 20: User’s Guide S544-5516
v IBM InfoPrint 20: Quick Setup Poster S544-5515
v IBM InfoPrint 20: Safety and Warranty Information G544-5524
These books are included with the optional network cards:
v IBM Network Printers: Ethernet and Token Ring Configuration Guide G544-5240
v IBM Network Printers: Twinax and Coax Configuration Guide G544-5241
These technical references must be ordered separately:
v IBM Network Printers: PCL5e and PostScript Level 2 Technical Reference S544-5344
v IBM Network Printers: IPDS and SCS Technical Reference S544-5312
About This Book 24
Chapter 1. Getting StartedIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Diagnostic Quick Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Error Codes and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Error Codes 00–19 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Error Codes 20–49 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Error Codes 50–99 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Print Quality Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Miscellaneous, Routine Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Completing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
IntroductionChapter 1. Getting Started quickly guides you through problem isolation.
“Defining the Problem” on page 26 reviews the information necessary to accurately define any printer problem.
With your printer problem defined, “Diagnostic Quick Path” on page 28 directs you to the correct diagnostic orrepair procedure.
See “Miscellaneous, Routine Tasks” on page 35 for miscellaneous or routine tasks.
“Completing Service” on page 36 is a quality-of-service assurance checklist.
© Copyright IBM Corp. 1998 25
Defining the ProblemUse the following as a guide for gathering information about the problem.1. Discuss the problem with the operator. Note information such as error messages, other symptoms (such
as print quality problems), what happened, what type of print job, and other recent problems. Review theprinter history with the customer and obtain or print a printer configuration page (see “Configuration Page”on page 250).
2. Switch on printer power. The printer performs a start-up diagnostic routine that checks the printer controllerand the printer. Almost all failures occurring during this start-up diagnostic routine and during WARM UPcause either an error code or a message.
3. Observe the display on the operator panel.
Note: See “Status Messages” on page 239 for messages displayed during normal operation.
v Is information correctly displayed?v Is the display blank, or does it display solid rectangles within approximately 2-minutes after power is
switched on?v Does WARMING UP display?v Does READY display within approximately 2-minutes?v Is there an error code or message?v View or print the error log looking for recent problems or patterns. See “Error Log” on page 254 for a
description of the error log.
v Try to duplicate the failure noting the following:– The printer fails to print a test print when not connected to a workstation or a network.– The printer fails to print when connected to a workstation, or an Ethernet, token-ring, coax, or twinax
configuration.– The printer prints, but the paper jams.
Chapter 1. Getting Started 26
– The printer prints, but has poor print quality.
Using this information, go to “Diagnostic Quick Path” on page 28.
Chapter 1. Getting Started 27
Solving the Problem
Diagnostic Quick PathUsing the problem information that you have gathered, go to Table 4 on page 29 below. Select the “Symptom ”and “Indication ” that most nearly defines your printer problem, and then “Go To ...” the suggested item toisolate the failure. See “Defining the Problem” on page 26 for a review of the information necessary toaccurately define any printer problem.
Note: See “Status Messages” on page 239 for messages displayed during normal operation.
Chapter 1. Getting Started 28
Table 4. “Diagnostic Quick Path”
Symptom Indication Go To...
Error code with amessage
Error codes 00–19 Table 5 on page 30
Error codes 20–49 Table 6 on page 31
Error codes 50–99 Table 7 on page 32
Message with No ErrorCode
WARMING UP (Always On)“Operator Panel, Controller, and Power Problems”on page 135
I/O INITIALIZING (Always On)“Ethernet / Token-Ring NIC Printing Problems” onpage 150
IBM INFOPRINT 20 (Always On)“Operator Panel, Controller, and Power Problems”on page 135
Other
Print quality problem Table 8 on page 34
Operator panel (blank, light or dark rectangles,pushbuttons), controller, or power problems
“Operator Panel, Controller, and Power Problems”on page 135
Problems printing from a Ethernet/Token-Ringconfiguration
“Ethernet / Token-Ring NIC Printing Problems” onpage 150
Problems printing from a Twinax/Coaxconfiguration
“Twinax / Coax NIC Printing Problems” onpage 179
EP (toner) cartridge is out of toner, and an errorcode 02 TONER LOW not displayed
“Toner Low and No Error Code 02 Displayed” onpage 142
Intermittent or Random Problems “Intermittent or Random Problems” on page 133
Miscellaneous, routine tasks Table 9 on page 35
Environmental problem (temperature, humidity,ventilation, space, supplies storage)
IBM InfoPrint 20: User’s Guide
Chapter 1. Getting Started 29
Error Codes and MessagesNote: See “Status Messages” on page 239 for status messages displayed during normal operation.
Error Codes 00–19 and Messages
From Table 5, select the “ Error Code Message ”, and then “ Go To ...” the suggested procedure to isolatethe problem.Table 5. Error Codes 00–19 and Messages
Error Codes 00–19 and Messages Error Codes 00–19 and Messages
Error Code Message Go To... Error Code Message Go To...
02 TONER LOW “02 TONER LOW” on page 4612 MANUALLY LOADpaper_size IN AUX
“12 MANUALLY LOAD paper_size INAUX” on page 64
03 2000 SHEET INPUTCOVER OPEN
“03 2000 SHEET INPUT COVEROPEN” on page 49
14 ADJUST PAPERGUIDES IN TRAY n
“14 ADJUST PAPER GUIDES INTRAY n” on page 64
04 TONER CART MISSING“04 TONER CART MISSING” onpage 50
15 2000 SHEET INPUTNOT READY
“15 2000 SHEET INPUT NOTREADY” on page 64
06 TOP COVER OPEN “06 TOP COVER OPEN” on page 52 16 TRAY n MISSING “16 TRAY n MISSING” on page 65
09 DUPLEX COVER OPEN“09 DUPLEX COVER OPEN” onpage 54
17 TRAY OPTION ERROR“17 TRAY OPTION ERROR” onpage 68
10 FUSER COVER OPEN“10 FUSER COVER OPEN” onpage 55
17 2000 SHEET INPUTERROR
“17 2000 SHEET INPUT ERROR” onpage 68
11 LOAD <size> IN<source>
“11 LOAD <size> IN <source>” onpage 58
Chapter 1. Getting Started 30
Error Codes 20–49 and Messages
From Table 6, select the “ Error Code Message ”, and then “ Go To ...” the suggested procedure to isolatethe problem.Table 6. Error Codes 20–49 and Messages
Error Codes 20–49 and Messages Error Codes 20–49 and Messages
Error Code Message Go To... Error Code Message Go To...
20 PAPER JAM “20 PAPER JAM” on page 69 31 MEMORY ALLOC ERROR“31 MEMORY ALLOC ERROR” onpage 101
21 PAPER JAM “21 PAPER JAM” on page 73 32 PRINT OVERRUN “32 PRINT OVERRUN” on page 101
22 PAPER JAM “22 PAPER JAM” on page 8340 MEMORY OPTIONERROR
“40 MEMORY OPTION ERROR” onpage 101
23 PAPER JAM “23 PAPER JAM” on page 8441 NETWORK OPTIONERROR
“41 NETWORK OPTION ERROR” onpage 102
24 PAPER JAM “24 PAPER JAM” on page 8942 NETWORK OPTIONERROR
“42 NETWORK OPTION ERROR” onpage 102
26 PAPER JAM “26 PAPER JAM” on page 94 43 PS OPTION ERROR“43 PS OPTION ERROR” onpage 103
27 PAPER ERROR<source>
“27 PAPER ERROR <source>” onpage 94
44 IPDS OPTION ERROR“44 IPDS OPTION ERROR” onpage 103
29 OUTPUT FULL “29 OUTPUT FULL” on page 98 45 OPTION ERROR “45 OPTION ERROR” on page 104
30 MEMORY OVERFLOW“30 MEMORY OVERFLOW” onpage 101
46 NETWORK OPTIONERROR
“46 NETWORK OPTION ERROR” onpage 104
Chapter 1. Getting Started 31
Error Codes 50–99 and Messages
From Table 7, select the “ Error Code Message ”, and then “ Go To ...” the suggested procedure to isolatethe problem.Table 7. Error Codes 50–59 and Messages
Error Codes 50–99 and Messages Error Codes 50–99 and Messages
Error Code Message Go To... Error Code Message Go To...
50 ERROR CALL FORSERVICE
“50 ERROR CALL FOR SERVICE”on page 105
71 DISK ERROR “71 DISK ERROR” on page 124
51 ERROR CALL FORSERVICE
“51 ERROR CALL FOR SERVICE”on page 108
72 DISK ERROR “72 DISK ERROR” on page 124
52 ERROR CALL FORSERVICE
“52 ERROR CALL FOR SERVICE”on page 109
73 DISK ERROR “73 DISK ERROR” on page 125
53 ERROR CALL FORSERVICE
“53 ERROR CALL FOR SERVICE”on page 114
80 ADD MEMORY FORIPDS
“80 ADD MEMORY FOR IPDS” onpage 125
54 ERROR CALL FORSERVICE
“54 ERROR CALL FOR SERVICE”on page 119
80 ADD MEMORY FORPAGES, ESC/P
“80 ADD MEMORY FOR PAGES,ESC/P” on page 125
55 ERROR CALL FORSERVICE
“55 ERROR CALL FOR SERVICE”on page 120
81 INSUFFICIENTMEMORY FOR IPDS
“81 INSUFFICIENT MEMORY FORIPDS” on page 125
56 ERROR CALL FORSERVICE
“56 ERROR CALL FOR SERVICE”on page 122
81 INSUFFICIENTMEMORY FOR PAGES
“81 INSUFFICIENT MEMORY FORPAGES” on page 125
61 ERROR CALL FORSERVICE
“61 ERROR CALL FOR SERVICE”on page 123
82 CX SEND STATE “82 HOST TIMEOUT” on page 126
62 ERROR CALL FORSERVICE
“62 ERROR CALL FOR SERVICE”on page 123
83 CX SEND STATE “83 CX SEND STATE” on page 126
63 ERROR CALL FORSERVICE
“63 ERROR CALL FOR SERVICE”on page 124
84 NO FONT SIMM FORPAGES, ESC/P
“84 NO FONT SIMM FOR PAGES,ESC/P” on page 126
Chapter 1. Getting Started 32
Print Quality ProblemsThe quality of the printed image depends upon many factors, some controlled by the customer and some byservice. The following customer controlled items should be as described in the IBM InfoPrint 20: User’s Guide:v Tonerv Paper, envelopes, or transparenciesv Consumable supplies replenished at the correct intervalsv Stable operating environment
– Temperature– Humidity
v Location– On a level surface– Proper ventilation– Shielded from direct rays from the sun– Low dust content– Not near water outlets, steamers, electric heaters, volatile gases, or open flame
v Supplies– Storage at the warehouse– Storage in the printer operating environment
Service should perform the following:v Replace worn partsv Check printer performance and print quality at every visit.
Chapter 1. Getting Started 33
Print Quality Defects
Before analyzing print quality (PQ) problems, verify that no supply item, such as the EP cartridge, needsreplacing. Also, check the items listed under “Print Quality Problems” on page 33.
From Table 8, select the “ Problem ”, and then “ Go To ...” the suggested procedure to isolate the failure.Table 8. Print Quality Diagnostics Quick Path
Problem Go To...
Background “Background” on page 184
Black Horizontal Stripes “Black Horizontal Stripes” on page 195
Black Prints “Black Prints” on page 188
Blank Prints “Blank Prints” on page 191
Damaged Print “Damaged Print” on page 196
Fusing “Fusing, Not Fused or Partially Fused Image” on page 200
Light (Undertoned) Prints “Light (Undertoned) Prints” on page 203
Residual Image “Residual Image” on page 208
Skewed Image “Skewed Image” on page 212
Spots “Spots” on page 216
Streaks, Horizontal “Streaks, Horizontal” on page 219
Streaks, Vertical “Streaks, Vertical” on page 223
Unusual Patterns “Unusual Patterns” on page 227
Voids “Voids” on page 229
Voids, Horizontal Band “Voids, Horizontal” on page 232
Voids, Vertical Band “Voids, Vertical” on page 236
Chapter 1. Getting Started 34
Miscellaneous, Routine TasksThis section guides you to performing routine printer tasks. When the tasks are completed, go to “CompletingService” on page 36.
From Table 9, select the “ Task ”, and then “ Go To ...” the suggested procedure.Table 9. “Routine Tasks”
Task Go To...
Cleaners “Cleaners and Lubricants” on page 588
Configuration page, running “Configuration Page” on page 250
Error log, using “Error Log” on page 254
Installing the printer IBM InfoPrint 20: User’s Guide
Locating assemblies and parts “Chapter 5. Locations” on page 360
Lubricants “Cleaners and Lubricants” on page 588
Power-Receptacle Safety-Check “Power-Receptacle Safety-Check” on page 17
Relocating the printer IBM InfoPrint 20: User’s Guide
Replenishing supplies IBM InfoPrint 20: User’s Guide
Run test prints “Test Prints” on page 251
Safety Inspection “Safety Inspection” on page 12
200K usage kit“Chapter 7. Preventive Maintenance and Usage Kit” onpage 543
Chapter 1. Getting Started 35
Completing ServiceNote: If you replaced a part that did not correct the problem, reinstall the original part.
If the printer has not been fixed using the procedures that you were directed to perform, return to “DiagnosticQuick Path” on page 28. Ensure that you have correctly interpreted the available information, and then definethe problem again. If a solution is not found, call your next level of support (see “Appendix D. TechnicalSupport” on page 602).
Use the following as a guide to ensure high quality printer operation:
1. Ensure the following:a. All internal cables and connectors are correctly connected.b. All covers, doors, panels, and trays are in place.c. Any workstation or network cable is connected.d. All power cords are connected.
2. Switch on printer power and ensure the following:a. IBM INFOPRINT 20 displays.b. WARMING UP displays.c. READY displays within approximately 2-minutes or the printer begins printing if a job is in the print
queue.3. Run test prints from the operator panel to ensure high quality output. Show these to the operator.4. Have the operator run a print job.5. Clean the work area.6. Clean the printer covers with a dry cleaning cloth; if necessary, use water and a mild detergent
(non-ammonia).7. Return control of the printer to the operator.
Chapter 1. Getting Started 36
Chapter 2. Diagnosing ProblemsGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Using Diagnostic Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Error Codes with Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4502 TONER LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4603 2000 SHEET INPUT COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4904 TONER CART MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5006 TOP COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5209 DUPLEX COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5410 FUSER COVER OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5511 LOAD <size> IN <source> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5812 MANUALLY LOAD paper_size IN AUX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6414 ADJUST PAPER GUIDES IN TRAY n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6415 2000 SHEET INPUT NOT READY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6416 TRAY n MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6517 TRAY OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6817 2000 SHEET INPUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6820 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6921 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7322 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8323 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8424 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8926 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9427 PAPER ERROR <source> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9429 OUTPUT FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9830 MEMORY OVERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10131 MEMORY ALLOC ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
© Copyright IBM Corp. 1998 37
32 PRINT OVERRUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10140 MEMORY OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10141 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10242 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10243 PS OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10344 IPDS OPTION ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10345 OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10446 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10450 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10551 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10852 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10953 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11454 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11955 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12056 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12261 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12362 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12363 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12471 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12472 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12473 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12580 ADD MEMORY FOR IPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12580 ADD MEMORY FOR PAGES, ESC/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12581 INSUFFICIENT MEMORY FOR IPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12581 INSUFFICIENT MEMORY FOR PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12582 HOST TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12683 CX SEND STATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12684 NO FONT SIMM FOR PAGES, ESC/P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Printer Problems without Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127Fuse or Power Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Chapter 2. Diagnosing Problems 38
Intermittent or Random Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133Operator Panel, Controller, and Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135Toner Low and No Error Code 02 Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Other Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14424V Power Supply to MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Ethernet / Token-Ring NIC Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163Paper Size Switch - 500-Sheet Paper Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165Pick Up Solenoid (Auxiliary Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176Twinax / Coax NIC Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191Black Horizontal Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195Damaged Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196Fusing, Not Fused or Partially Fused Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Light (Undertoned) Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208Skewed Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216Streaks, Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219Streaks, Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223Unusual Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Chapter 2. Diagnosing Problems 39
Voids, Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232Voids, Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Chapter 2. Diagnosing Problems 40
General InformationThe Diagnostic Quick Path should have directed you to this section to analyze your printer problem.
1. Diagnostics assume there are no code problems in the printer controller. If you are unable to fix aproblem using the diagnostics, we recommend that you replace the printer controller and obtain the latestlevel code.
2. Diagnostics frequently use new or ″known good″ components as diagnostic tools. We recommend youcarry a spare Toner Cartridge (EP Cartridge), MCU PWB, Printer Controller PWB, and Power SupplyPWB.
3. Unless indicated otherwise, the instruction ″switch ON main power″ means for you to SWITCH ON printerpower and let the printer proceed through power-on diagnostics and warm-up until it is on-line and readyto print.
4. Unless indicated otherwise, you should inspect and confirm the status of those components listed underthe title of ″SUSPECT COMPONENTS″ at the first part of each diagnostic. The inspection items are:v Installed properly?v Not damaged or deformed?v Not contaminated with foreign material?
5. If you cannot isolate the problem using the diagnostics, replace each component listed under the title of″SUSPECT COMPONENTS″ at the first part of each diagnostic, one at a time, until the problem is fixed.
6. Conventions used to represent connectors,v P/J XX means that the Plug and its corresponding Jack are connected.v PXX means that the Plug is disconnected. (Unless this plug is soldered to a PWB).v JXX means that the Jack is disconnected. (Unless this jack is soldered to PWB).
7. When you are instructed to take a voltage reading between ″P/J A-B and P/J X-Y″, place the red probe(+) of your meter on pin B of P/J A, and place the black probe (-) of your meter on pin Y of P/J X.
8. When you are instructed to take a voltage reading between ″P/J X and P/J Y″ (without specified pinnumbers), check all voltage carrying pins. See the Wiring Diagrams for signals and pin numbers.
Chapter 2. Diagnosing Problems 41
9. Plug numbers are indicated on the circuit board. In there are 8 pins in a plug, you can find a 1 (or A) atone end and an 8 or (H) at the other end. The other pins, such as 6, are found by counting from oneend.
10. When you are instructed to take a voltage reading, the black probe (-) is generally connected to a pinthat is either RTN (Return) or FG (Frame Ground) in place of any SG pin or test point.
11. Unless an diagnostic instructs you otherwise, before measuring voltages make sure the printer isswitched ON, the Print Cartridge and the Paper Cassette are installed, and the Exit Cover is closed(Interlock Switch is actuated).
12. All voltage values given in the diagnostics are approximate. Measured voltages may vary more than 25%from the values stated in the diagnostics. The main purpose of most voltage readings taken in thediagnostics is to determine whether or not a component is receiving the correct high voltage value fromthe power supply and if gating (a voltage drop) occurs during component actuation. Gating signals maybe nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossibleto read on a multimeter.
13. Diagnostics may instruct you to remove or replace a component. See “Chapter 6. Removal Procedures,Adjustments” on page 394 for information on how to remove and reinstall a component.
14. When a diagnostic instructs you to replace a component and that component is part of a larger assembly,you should replace the entire assembly.
Chapter 2. Diagnosing Problems 42
Using Diagnostic Tables1. Each numbered step in a diagnostic instructs you to perform a certain action or procedure.2. The action box may contain additional information and numbered substeps to perform the action.3. The action is followed by a question.4. If your response to the question is Yes, follow the instructions for a Yes reply.5. If your response to the question is No, follow the instructions for a No reply.6. Diagnostics often ask you to take voltage readings at certain test points. “Chapter 4. Circuit Diagrams” on
page 307 and “Chapter 5. Locations” on page 360 contain information on test point locations and signalnames.
7. Diagnostics often ask you to replace a printer component. “Chapter 6. Removal Procedures, Adjustments”on page 394 provides detailed steps for removing and replacing all major parts of the printer.
Chapter 2. Diagnosing Problems 43
Diagnostics“Diagnostic Quick Path” on page 28 is the entry point for all problems. If at any point the diagnostic to whichyou have been directed does not solve the problem, return to the Diagnostic Quick Path.
Diagnostics are listed as follows:
1. “Error Codes with Messages” on page 45Error codes with messages are described here.
2. “Printer Problems without Error Codes” on page 127You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post anerror code.
3. “Other Diagnostics” on page 144These are secondary diagnostics pointed to by other diagnostics.
4. “Print Quality” on page 184Each of these diagnostics has an illustration of the print quality symptom discussed in the diagnostic.
Chapter 2. Diagnosing Problems 44
Error Codes with MessagesError codes (listed numerically) with messages are described here.
Chapter 2. Diagnosing Problems 45
02 TONER LOW
Meaning : The EP Cartridge is nearing end-of-life and should be replaced. This error can also occur if the EPCartridge is misaligned, caused by the side guides or BTR assembly.
Action : Press the Continue key to continue printing (the TONER LOW message remains on the display).Ensure that a new EP cartridge is available. When the print quality becomes unacceptable, install a new EPcartridge.
The TONER LOW item on the Paper Menu lets you specify whether or not you want the printer to stopprinting when it detects a TONER LOW condition.
If toner is low and error code 02 does not display, go to “Toner Low and No Error Code 02 Displayed” onpage 142.
If this action does not fix the problem, go to Table 10.Table 10. 02 TONER LOW
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v Toner Sensor Assembly (Asm-Index: 5-13, page 557)
v Toner Relay Harness (Asm-Index: 12-18, page 575)
v MSI Bracket Assembly (Asm-Index: 5-7, page 557)
v MCU PWB (Asm-Index: 12-8, page 575)
1.EP CARTRIDGE
Install a new EP Cartridge.
Does the Error Code 02 TONER LOW still appear?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
Chapter 2. Diagnosing Problems 46
Table 10. 02 TONER LOW (continued)
Step Actions and Questions Yes No
2.
FUNCTION OF TONER SENSORa. Use “D21 SENSOR TEST” on page 261 to check the function of the Toner
Sensor Assembly.Note: The Pop Up Unit must be closed in the next step.
b. Depress the switch with a non-magnetized piece of steel.
Does the Toner Sensor function correctly?
Replace theMCU, or there isan EP cartridgealignmentproblem.
Go to step 3
3. TONER SENSOR CONNECTION
Is the Toner Sensor connection (P/J221) OK?
Go to step 4 Repair as needed
4.TONER SENSOR ASSEMBLY (Asm-Index: 5-13, page 557)
Install a new Toner Sensor Assembly (See page 462).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 5
5.
TONER RELAY HARNESS
Inspect the Toner Relay Harness (P/J22 at the MCU; P/J222 at the TonerSensor Harness).
Is the harness OK?
Go to step 6 Repair as needed
6.MSI BRACKET ASSEMBLY (Asm-Index: 5-7, page 557)
Replace the MSI Bracket Assembly (See page 457).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to the laststep of thisdiagnostic.
Chapter 2. Diagnosing Problems 47
Table 10. 02 TONER LOW (continued)
Step Actions and Questions Yes No
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 48
03 2000 SHEET INPUT COVER OPEN
Meaning : The cover at the back of the 2000-Sheet Input Drawer is open.
Action : Close the cover. If the message persists, make sure both corners of the cover are completely closed.Also check for paper inside the cover.
Error Code Diagnostic Procedure : “03 2000-SHEET COVER OPEN” on page 708.
Chapter 2. Diagnosing Problems 49
04 TONER CART MISSING
Meaning : The EP Cartridge is not in place or is installed incorrectly.
Action : Open the printer and make sure the EP cartridge is seated correctly. If you have not installed a EPcartridge, do so now.
If this action does not fix the problem, go to Table 11.Table 11. 04 TONER CART MISSING
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v CRU Sensor Assembly (Asm-Index: 11-15, page 572), includes cable
v MCU PWB (Asm-Index: 12-8, page 575)
1.Install a new EP Cartridge.
Does the LCD display a 04 TONER CART MISSING?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)
Press and release the CRU Sensor Assembly.
Does the CRU Sensor Assembly lever move smoothly?
Go to step 3 Replace the CRUSensor Assembly(See page 503)
3.
FUNCTION OF CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)
a. Use “D21 SENSOR TEST” on page 261 to check the function of the CRUSensor Assembly.
b. Actuate the CRU Sensor Assembly.
Does the CRU Sensor function correctly?
Possibleintermittent orrandom problems(See page 133)
Go to step 4
Chapter 2. Diagnosing Problems 50
Table 11. 04 TONER CART MISSING (continued)
Step Actions and Questions Yes No
4.CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)
Replace the CRU Sensor Assembly (See page 503).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 5
5.FRAME ALIGNMENT
When you close the top cover, is the CRU Sensor activated?
Replace the MCUPWB (See page526 or 529)
Repair as needed
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 51
06 TOP COVER OPEN
Meaning : The top cover is open.
Action : Close the cover.
If this action does not fix the problem, go to Table 12.Table 12. 06 TOP COVER OPEN
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Interlock Switch (Asm-Index: 12-1, page 575)
v Interlock Actuator (Asm-Index: 11-19, page 572)
v ROS Support (Asm-Index: 11-18, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1.
INTERLOCK SWITCH (Asm-Index: 12-1, page 575) and INTERLOCKACTUATOR (Asm-Index: 11-19, page 572)
a. Open and close the Pop Up Unit.b. Inspect the movement of the Interlock Switch.
Does the actuator tab press down on the Interlock Switch lever?
Go to step 2 Replace theInterlock Actuatoror the InterlockSwitch (See page513)
2.
FUNCTION OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575)
a. Use “D21 SENSOR TEST” on page 261 to check the Interlock Switch.
b. Open and close the Pop Up Unit.
Does the Interlock Switch function correctly?
Possibleintermittent orrandom problems(See page 133)
Go to step 3
Chapter 2. Diagnosing Problems 52
Table 12. 06 TOP COVER OPEN (continued)
Step Actions and Questions Yes No
3.
CONTINUITY OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575)
a. Remove the Controller Assembly (See page 535).
b. Disconnect P/J21 and P/J123.c. Press and release the Interlock Switch.d. Check for the continuity between J21-1 <=> J123-1.
Is there continuity between J21-1 <=> J123-1 when you press theInterlock Switch and no continuity when you release it?
Go to step 4 Replace theInterlock Switch(See page 513)
4.
LVPS ASSEMBLY (Asm-Index: 12-4, page 575)
a. Reconnect P/J21 from the MCU PWB and P/J123 from the LVPSAssembly.
b. Open and Close the Pop Up Unit.c. Measure the voltage between P/J21-1 <=> P/J11-1.
Is the voltage between P/J21-1 <=> P/J11-1 24VDC when you close thePop Up Cover Assembly, and 0VDC when you open it?
Replace the MCUPWB (See page526 or 529)
Verify that thecover activatesthe sensorcorrectly, thenreplace the LVPSAssembly (Seepage 521)
5.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 53
09 DUPLEX COVER OPEN
Meaning : A cover on the duplex unit is open.
Action : Make sure both duplex covers are closed.
Error Code Diagnostic Procedure : “09 DUPLEX COVER OPEN” on page 607.
Chapter 2. Diagnosing Problems 54
10 FUSER COVER OPEN
Meaning : The Fuser Cover (the Main Interlock Switch) is open.
Action : Close the cover.
If this action does not fix the problem, go to Table 13.Table 13. 10 FUSER COVER OPEN
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Duplex Interface PWB (Asm-Index: 12-6, page 575) or it’s MCU connectionNote: The Duplex Interface PWB can appear to be seated when it is not.
v Fuser Cover Switch (Asm-Index: 12-2, page 575)
v Fuser Cover Assembly (Asm-Index: 1-1, page 548)
v MCU PWB (Asm-Index: 12-8, page 575)
v Fuser Switch Cover Harness (Asm-Index: 12-13, page 575)
1.
FUSER COVER SWITCH (Asm-Index: 2-2, page 550)
a. Open and close the Fuser Cover Assembly (Asm-Index: 1-1, page 548).
b. Inspect the contact of the Fuser Cover with the Fuser Cover Switch(Asm-Index: 12-2, page 575).
c. Ensure the switch is installed properly and the bracket is not bent.d. Push and release the Fuser Cover Switch manually.
Does the Fuser Cover Assembly actuate the Fuser Cover Switch, anddoes the Fuser Cover Switch move smoothly?
Go to step 2 Replace theFuser CoverAssembly (Seepage 400) or theFuser CoverSwitch (See page516)
Chapter 2. Diagnosing Problems 55
Table 13. 10 FUSER COVER OPEN (continued)
Step Actions and Questions Yes No
2.
CONTINUITY OF FUSER COVER SWITCH (Asm-Index: 12-2, page 575)
a. Open the Fuser Cover (Asm-Index: 1-2, page 548).
b. Remove the Fuser Cover Switch (See page 516).
c. Unplug P/J190 from the Fuser Cover Switch (See page 516).
d. Press and release the actuator of the Fuser Cover Switch.e. Check continuity from 1A to 1B, and 2A to 2B on the Fuser Cover Switch
(the pins are labeled in the plastic on the bottom of the switch).
Is there continuity on the pair of switch pins when you press theactuator and no continuity when you release it?
Go to step 3 Replace theFuser CoverSwitch (See page516)
3.
DUPLEX INTERFACE PWB (Asm-Index: 12-6, page 575)
a. Remove the Controller Assembly (See page 535).
b. Find the Duplex Interface PWB. It is the small board that bridges theduplex option connector (above the power connector) to the MCU PWB(P/J18).
c. Ensure that the connector between the MCU PWB (P/J18) and the DuplexInterface PWB is properly seated.
Note: The Duplex Interface PWB can appear to be seated when it is not.
Is the Duplex Interface PWB properly seated?
Go to step 4 Reconnect P/J18.Verify the fix. Alsoverify that theproblem jobprints.
4.The Fuser Cover harness connects to the Duplex Interface PWB at P/J180.This connector is located on the top on the Duplex Interface PWB. P/J180 canbe easily damaged.
Is P/J180 OK?
Go to step 5 Replace theDuplex InterfacePWB (See page524).
Chapter 2. Diagnosing Problems 56
Table 13. 10 FUSER COVER OPEN (continued)
Step Actions and Questions Yes No
5.
One of the following parts is bad:v Duplex Interface PWB (Asm-Index: 12-6, page 575)
v Fuser Cover Harness (Asm-Index: 12-13, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 57
11 LOAD <size> IN <source>
Meaning : The tray is out of paper, the tray contains the wrong size paper, or the tray is loaded incorrectly. Themessage identifies the size of paper (size) and the tray (source) that needs paper. If the message indicates atray you do not think you specified, automatic tray switching may be enabled. This error can occur if paperempty or size sensing is bad in any paper source.
Actions :v If the tray is empty, fill it. The printer will resume printing.v If the tray contains the wrong size paper, you have two choices: to use the current paper size, press the
Continue key; otherwise, load the correct paper size into the tray.v If the tray contains the right size paper, make sure the paper is loaded correctly. Check the paper guides.
The AUTOSENSED PAPER section of the printer configuration page shows what size paper the printerpaper size sensors have determined is in each tray.
v If the tray is empty, refill it. The printer will resume printing.v If you are printing a printer configuration page, make sure Letter or A4 size paper is loaded in the default
tray.
Chapter 2. Diagnosing Problems 58
Table 14. 11 LOAD <size> IN <source>
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Problems only from Auxiliary Tray:– PAPER MENU/AUXSIZE setting wrong– MSI No Paper Sensor (Asm-Index: 5-9, page 557), includes harness
– MSI No Paper Actuator (Asm-Index: 5-10, page 557)
v Tray empty problems only from Tray 1:– Cassette No Paper Sensor (Asm-Index: 3-11, page 553)
– Cassette No Paper Actuator (Asm-Index: 3-16, page 553)
– Feeder Harness (Asm-Index: 3-12, page 553)
v Tray size problems with Tray 1 and possibly Tray 2 or 3v Feeder PWB (Asm-Index: 3-1, page 553)
v Tray Harness (Asm-Index: 12-17, page 575)
v Problems only with one Optional Tray:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page
697)
– 2000-Sheet Input Option: Analyze using “Appendix H. 2000-Sheet InputDrawer Option” on page 703
v General:– MCU PWB (Asm-Index: 12-8, page 575)
Chapter 2. Diagnosing Problems 59
Table 14. 11 LOAD <size> IN <source> (continued)
Step Actions and Questions Yes No
1.
TRAY EMPTY SENSINGa. During the next steps, record which sources print OK and which sources
are involved with the problem. Clear jams (open and close the top cover)as necessary. Note that CONFIG PAGES will try a reprint after the jam iscleared — you can press ONLINE to cancel.
b. Set PAPER MENU/TRAYSWITCH=OFF.Note: Tray switching may affect behavior with real jobs. CONFIG pages willtry to print only on Letter or A4 paper that is loaded.c. Load Tray 1 (the standard 500 sheet input) with letter or A4 paper (empty
all other paper sources). Set the PAPER MENU/SOURCE=TRAY 1. Try toprint using TEST MENU/CONFIG PAGE. If a jam occurs, clear it.
d. Load the Auxiliary Tray (the flip-down MSI input at the front of the printer).Ensure that PAPER MENU/ AUXSIZE matches the loaded papersize/orientation. Set PAPER MENU/SOURCE=AUX. Try to print anotherCONFIG PAGE.
e. If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeatthe above steps for Tray 2.
f. If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 3.
Did the 11 LOAD <size> IN <source> ever occur?
Look at aCONFIG pagefrom anothersource. Verify thatthe loaded papermatchesAUTOSENSEDPAPER details. Ifnot, go to “PaperSize Switch -500-Sheet PaperTrays” onpage 165. IfAUTOSENSEDPAPER is OK, goto step 2.
For othermessages orsymptoms, go to“Chapter 1.Getting Started”on page 25. If
there is nomessage, theuser may besending jobs witha size/sourcemismatch.
2.
Does the problem appear when using Tray 2 or 3? Go to “11 LOAD<size> IN TRAYn” on page 663.Or analyze using“Appendix H.2000-Sheet InputDrawer Option” onpage 703.
Go to step 3
Chapter 2. Diagnosing Problems 60
Table 14. 11 LOAD <size> IN <source> (continued)
Step Actions and Questions Yes No
3. Does the 11 LOAD <size> IN <source> error code appear when you feedpaper from Auxiliary Tray (MSI)?
Go to step 4 Go to step 8
4.
MSI NO PAPER ACTUATOR (Asm-Index: 5-10, page 557)
Insert then remove a piece of paper into the Multi Sheet Inserter.
Do the MSI No Paper Actuator move smoothly when paper is insertedthen removed?
Go to step 5 Repair or replacethe MSI No PaperActuator (Seepage 460)
5.
MSI NO PAPER SENSORa. Use “D21 SENSOR TEST” on page 261 to check the MSI No Paper
Sensor (Asm-Index: 5-9, page 557).
b. Press and then release the MSI No Paper Actuator.
Does the MSI No Paper Sensor work correctly?
Go to step 8.Possibleintermittent orrandom problems(See page 133)
Go to step 6
6.
Replace the following:v MSI Bracket Assembly (See page 457)
v MSI No Paper Sensor (See page 460)
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 7
7.
The MSI no paper sensing problem could be caused by one of the following:v MCU PWB (Asm-Index: 12-8, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
Chapter 2. Diagnosing Problems 61
Table 14. 11 LOAD <size> IN <source> (continued)
Step Actions and Questions Yes No
8.
PAPER CASSETTE (Asm: 2, page 550)
There is problem with Tray 1 no paper sensing.
a. Remove the Paper Cassette from the printer.b. Remove the Cassette Cover (Asm-Index: 2-25, page 550) and all paper
from the Paper Cassette.
c. Insert the Paper Cassette into the printer and inspect the Bottom PlateAssembly (Asm-Index: 2-10, page 550).
Is the Bottom Plate Assembly raised?
Go to step 9 Replace thePaper Cassette
9.CASSETTE NO PAPER ACTUATOR (Asm-Index: 3-16, page 553)
Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553).
Does the Cassette No Paper Actuator move smoothly?
Go to step 10 Replace theCassette NoPaper Actuator(See page 436)
10.
CASSETTE NO-PAPER SENSOR (Asm-Index: 3-11, page 553)
a. Use “D21 SENSOR TEST” on page 261 to check the Cassette No PaperSensor.
b. Release the tray 1 Low Paper Actuator (Asm-Index: 3-10, page 553)
c. Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553).
Does the Cassette No Paper Sensor function correctly?
Possibleintermittent orrandom problems(See page 133)
Go to step 11
11.CASSETTE NO PAPER SENSOR (Asm-Index: 3-11, page 553)
Replace the Cassette No Paper Sensor (See page 430).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 12
Chapter 2. Diagnosing Problems 62
Table 14. 11 LOAD <size> IN <source> (continued)
Step Actions and Questions Yes No
12.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 63
12 MANUALLY LOAD paper_size IN AUX
Meaning : The auxiliary tray requires paper. The message indicates the required size (paper_size).
Action : Place another sheet of paper or other media in the auxiliary tray and press the Continue key. If youreceive this message and you do not want the manual printing function, set MANUAL to OFF on the PaperMenu or using your printer driver.
14 ADJUST PAPER GUIDES IN TRAY n
Meaning : Paper guides in the specified tray need adjusting.
Action : Adjust the paper guides.
15 2000 SHEET INPUT NOT READY
Meaning : The elevator mechanism in the 2000-Sheet Input Drawer is moving or out of position.
Action : Wait for the elevator to stop moving. Make sure the 2000-Sheet Input Drawer is in place.
Error Code Diagnostic Procedure : “15 TRAY n NOT READY” on page 709.
Chapter 2. Diagnosing Problems 64
16 TRAY n MISSING
Meaning : Paper Cassette (Tray 1), Tray 2 or Tray 3 are not in place.
Action : Open and close the tray. If you have not installed the tray, do so at this time.
If this action does not fix the problem, go to Table 15.Table 15. 16 TRAY n MISSING
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Tray 1 Problems:– Feeder PWB (Asm-Index: 3-1, page 553)
– Cassette Guide L (Asm-Index: 3-7, page 553)
– Paper Cassette (Asm: 2, page 550)
v Tray 2 Problems:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page
697)
v Tray Harness (Asm-Index: 12-17, page 575)
v General:– MCU PWB (Asm-Index: 12-8, page 575)
1.
Does the Error Code specify Tray 2 or Tray 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661
Go to step 2
Chapter 2. Diagnosing Problems 65
Table 15. 16 TRAY n MISSING (continued)
Step Actions and Questions Yes No
2.Remove and reinstall the affected paper cassette (Asm: 2, page 550).
Does the 16 TRAY n MISSING error code still appear?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
3.
PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS
Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page553).Note: If the switches are activated, answer No to the following question.
Do the Size Cam states match the loaded paper size? (see “Paper SizeSwitch - 500-Sheet Paper Trays” on page 165)
Go to step 5 Go to step 4
4.
PAPER SIZE CAM (Asm-Index: 2-20, page 550) MECHANICS
Inspect the suspect components and their settings relating to the Size Camas:
v End Guide Plate (Asm-Index: 2-14, page 550)
v Paper End Guide (Asm-Index: 2-15, page 550)
v End Guide Spring (Asm-Index: 2-16, page 550)
v End Guide (Asm-Index: 2-17, page 550)
v Pivot Plate (Asm-Index: 2-18, page 550)
v Sector Gear (Asm-Index: 2-19, page 550)
v Size Cam
Is there any damage or wrong setting on those suspect components?
Replace damagedparts, adjustsetting, or install anew cassette
Go to step 6
Chapter 2. Diagnosing Problems 66
Table 15. 16 TRAY n MISSING (continued)
Step Actions and Questions Yes No
5.
PAPER SIZE SWITCHa. Remove the Paper Cassette (Asm: 2, page 550).
b. Use “D21 SENSOR TEST” on page 261 to check the function of the PaperSize Switch.
c. Reach inside the paper feeder and press and release each Size Actuator(Asm-Index: 3-8, page 553), one Actuator at a time, pressing ENTERbetween each Actuator tested.
Do the Size Switches function correctly?
Replace the MCUPWB (See page526 or 529)
Go to “Paper SizeSwitch -500-Sheet PaperTrays” onpage 165
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 67
17 TRAY OPTION ERROR
Meaning : An optional paper tray was detected previously, but is no longer detected.
Action : Make sure that the tray is installed correctly.
Error Code Diagnostic Procedure : “17 TRAY n OPTION ERROR” on page 664.
17 2000 SHEET INPUT ERROR
Meaning : The 2000-Sheet Input Drawer is not ready.
Action : Make sure that the 2000-Sheet Input Drawer has power and is properly installed.
Error Code Diagnostic Procedure : “17 2000 SHEET INPUT ERROR” on page 710.
Chapter 2. Diagnosing Problems 68
20 PAPER JAM
Meaning : There is a paper jam at the Exit Sensor (Exit Photo Sensor).
Action : Remove jammed paper from the paper path. Open and close the top cover.
If this action does not fix the problem, go to Table 16.Table 16. 20 PAPER JAM
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor
v Duplex Unit (Asm: 30, page 652)
v MCU PWB (Asm-Index: 12-8, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
v Exit Cover (Asm-Index: 1-12, page 548)
1. PAPER CONDITIONS
Is the paper wrinkled, damaged, or damp?
Replace withfresh, dry paper
Go to step 2
2. Switch ON main power.
Is 20 PAPER JAM displayed when you Switch ON power?
Go to step 3 Go to step 5
3.
PAPER AT EXIT ACTUATOR (Asm-Index: 8-24, page 564)
a. Open the Fuser Cover.b. Open the Fuser Access Cover.
Is there paper at the Exit Actuator inside the Fuser?
Remove thepaper. Go to step4.
Go to step 10
Chapter 2. Diagnosing Problems 69
Table 16. 20 PAPER JAM (continued)
Step Actions and Questions Yes No
4.Is the Error Code 20 PAPER JAM gone? Verify the fix. Also
verify that theproblem jobprints.
Go to step 5
5.
DUPLEX UNIT (Asm-Index: 30-1, page 652)
Does the problem appear using the Duplex Unit?
Ensure that theDuplex Unit isinstalled correctlyand plugged intothe duplexconnection. If it is,go to“Appendix E.Duplex UnitOption” onpage 604.
Go to step 6
6.
CAUTION:<2-35> Remove all watches, rings, jewelry, and other articles(such as a necktie) that may catch on printer parts beforeworking in this area.
ROTATION OF EXIT ROLL ASSEMBLY (Asm-Index: 9-31,page 567)
a. Switch ON main power.b. Inspect the rotation of the Exit Roll Assembly and the Pinch
Roll of the Fuser Top Cover Assembly (Asm-Index: 8-6, page564) during the warm up period.
Does the Exit Roll Assembly and the Pinch Roll of the FuserTop Cover Assembly rotate smoothly?
Go to step 7 Replace theFuser Assembly(See page 487)
Chapter 2. Diagnosing Problems 70
Table 16. 20 PAPER JAM (continued)
Step Actions and Questions Yes No
7.
EXIT ROLL ASSEMBLY (Asm-Index: 9-31, page 567)
a. Run a Test Print.b. Inspect the paper path through Exit Roll Assembly and the Pinch Roll of
the Fuser Top Cover Assembly (Asm-Index: 8-6, page 564).
Does the paper pass through the Exit Roll Assembly and the Pinch Rollof the Fuser Top Cover Assembly?
Go to step 8 Replace theFuser Assembly(See page 487)
8.PAPER CASSETTE
Does Error Code 20 PAPER JAM appear only when using the PaperCassette?
Go to “27 PAPERERROR<source>” onpage 94
Go to step 9
9.
EXIT ACTUATOR (Asm-Index: 8-24, page 564)
a. Remove the Exit Cover (See page 414).
b. Open the Fuser Cover (Asm-Index: 1-2, page 548) and the Fuser RearCover (Asm-Index: 8-11, page 564).
c. Actuate and release the Exit Actuator.d. Inspect the position of the lever.
Is the arm of the Exit Actuator away from the detecting points of the ExitSensor when you actuate the Actuator, and does the arm shield thedetecting points when you release it?
Go to step 10 Replace theFuser Assembly(See page 487)
10.
EXIT SENSOR (Asm-Index: 8-25, page 564)
Use “D21 SENSOR TEST” on page 261 to check the Exit Sensor function (youwill need to override the fuser cover switch).
Does the Exit Sensor function correctly?
Bad MCU PWB(See page 526 or529), or possibleintermittent orrandom problems(See page 133)
Go to step 11
Chapter 2. Diagnosing Problems 71
Table 16. 20 PAPER JAM (continued)
Step Actions and Questions Yes No
11.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
Replace the Fuser Assembly (See page 487).Note: The Fuser is part of the Usage Kit.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 12
12.
The Fuser exit sensing is bad, one of the following parts is bad:v High Harness Assembly (Asm-Index: 6-5, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
13.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 72
21 PAPER JAM
Meaning : Misfeed jam. There is a paper jam between the paper inputs (Tray 1, 2, 3, AUX Tray) and theRegistration Sensor.
Action : Remove jammed paper from the paper path. Make sure paper is loaded correctly. Open and close thetop cover.
Note: If the 21 PAPER JAM error occurs only when paper re-enters the printer from the duplex option, go to“22 PAPER JAM (or 21 PAPER JAM from Duplex)” on page 608.
SUSPECT COMPONENTS
v Jams only from Auxiliary Tray:– Transport Chute Assembly (Asm-Index: 6-2, page 559)
– MSI No Paper Sensor (Asm-Index: 5-9, page 557)
– MSI No Paper Actuator (Asm-Index: 5-10, page 557)
– Pick Up Solenoid (Asm-Index: 6-17, page 559)
– Pick Up Roll (Asm-Index: 6-9, page 559)
– Retard Pad Assembly (Asm-Index: 6-18, page 559)
– Front Bottom Tray (Asm-Index: 5-5, page 557)
v Jams only from Tray 1:– Cassette No Paper Sensor (Asm-Index: 3-11, page 553)
– Cassette No Paper Actuator (Asm-Index: 3-16, page 553)
– Feed Solenoid (Asm-Index: 4-8, page 555)
– Feed Roll (Asm-Index: 4-1, page 555)
– Feeder Harness (Asm-Index: 3-12, page 553). Use P/N 90H0775.
Chapter 2. Diagnosing Problems 73
v Jams from Tray 1 and possibly Tray 2 or 3:– Electromagnetic Clutch, Turn Roll (Asm-Index: 4-9, page 555)
– Turn Roll Assembly (Asm-Index: 4-10, page 555)
– Rear Roll Assembly (Asm-Index: 4-11, page 555)
– Feeder PWB (Asm-Index: 3-1, page 553)
– Turn Chute Assembly (Asm-Index: 3-5, page 553)
– Turn In Chute (Asm-Index: 3-4, page 553)
– Paper Cassette (Asm: 2, page 550)
– Tray Harness (Asm-Index: 12-17, page 575)
v Jams from any Tray:– Registration Sensor (Asm-Index: 7-6, page 562)
– Registration Actuator (Asm-Index: 7-7, page 562)
– High Harness Assembly (Asm-Index: 6-5, page 559)
v 500-Sheet Paper Tray Option Problems:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697)
v 2000-Sheet Input Drawer Problems:– Treat as a “26 PAPER JAM” on page 94
v General:– MCU PWB (Asm-Index: 12-8, page 575)
– Main Gear Assembly (Asm-Index: 10-10, page 570)
– Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
Chapter 2. Diagnosing Problems 74
Table 17. 21 PAPER JAM
Step Actions and Questions Yes No
1.
PAPER CONDITIONS AND ADJUSTMENTSv The paper should not be curled, damaged, or damp.v The paper should fit precisely within the guides of the tray cassette. If you
are using the Auxiliary Tray (MSI), the PAPER MENU/AUXSIZE settingmust match the size and orientation (LEF=Long Edge Feed, SEF=ShortEdge Feed).
Are the paper and paper adjustments OK?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.
PAPER JAM
Clear all paper in the paper path.
Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also seeTable 58 on page 293.
Is the Registration Actuator operating correctly?
Go to step 3. Repair or replacethe RegistrationActuator(Asm-Index: 7-7,page 562).
Chapter 2. Diagnosing Problems 75
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
3.
DETERMINE WHICH SOURCE(S) ARE INVOLVED WITH THE PAPER JAMv Load all sources with paper.v Switch the printer power ON.v If a jam message is displayed, clear the entire paper path. If an error other
than 21 PAPER JAM occurs, go the appropriate error code procedure.v Set PAPER MENU/TRAYSWITCH=OFF.v During the next steps, record which sources print OK and which sources
are involved with jams. Clear jams as necessary. Note that CONFIGPAGES will try a reprint after the jam is cleared. Press ONLINE to cancel.
v Load Tray 1 (the standard 500 sheet input). Set the PAPERMENU/SOURCE=TRAY 1. Try to print using TEST MENU/CONFIG PAGE. Ifa jam occurs, clear it.
v Load the Auxiliary Tray (the flip-down MSI input at the front of the printer).Ensure that PAPER MENU/ AUXSIZE matches the loaded papersize/orientation. Set PAPER MENU/SOURCE=AUX. Try to print anotherCONFIG PAGE.
v If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 2.
v If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 3.
Did the 21 PAPER JAM ever occur?
Record therelated printsources, and goto step 8
Go to step 4
4.Repeat the above step using TEST MENU/CONTINUOUS TEST. (Stop theContinuous Test with the CANCEL PRINT key; 10 pages may print before theprinter stops.)
Is the printing OK?
Go to step 6 Go to step 5
Chapter 2. Diagnosing Problems 76
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
5.Did 21 PAPER JAM occur? Record the
related printsources, and goto step 8.
For other errors,return to“Diagnostic QuickPath” on page 28.
6.
DUPLEX UNIT (Asm: 12, page 575)
If a duplex option is not installed, go to step 7.
If a duplex option is installed, set PAPER MENU/DUPLEX=ON. Print usingTEST MENU/CONTINUOUS TEST.
Is duplex printing OK?
Go to step 7 See “Appendix E.Duplex UnitOption” onpage 604. Go tostep 7
7.
PAPER OUT SENSING
From each source, remove all paper. Verify that printing a CONFIG PAGEfrom that source causes an 11 LOAD <size> IN <source> error.
Is the paper out sensing for each source OK?
Possibleintermittent orrandom problems,see page 133
Paper out sensingproblem. (For500-sheet option,replace the500-sheet option)
8.
Use the following chart to determine which step to go to (ignore references tooptions not installed).Aux Tray 1 Tray 2 Tray 3 Go to step:
OK OK bad bad 10OK OK OK bad 10bad OK OK OK 12bad bad bad bad 16OK bad bad bad 9
9.TRAY 1 PRINTING IS BAD
Observe the position of the paper from Tray 1 after the error occurs.
Did the paper start to leave the cassette?
Turn Rollproblem. Go tostep 21.
Pick problem. Goto step 18.
Chapter 2. Diagnosing Problems 77
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
10.
Is the failing Tray a 500 sheet input option?Note: If Tray 2 and Tray 3 printing is bad, Tray 2 is the failing tray.
Go to step 11 The failing tray isthe 2000-SheetInput Drawer. Goto “26 PAPERJAM” onpage 711.
11.
TRAY SPRINGSv Remove the tray (cassette) from the option. Remove the paper.v Press the bottom plate down and ensure that it stays down.v Insert the tray in the option and ensure that the plate springs up.v Inspect the tray for other damage.v If another tray is available, use it for analysis.
Is the tray OK?
Replace the entire500-Sheet inputoption
Replace the tray
12.
FRONT BOTTOM TRAY (Asm-Index: 5-5, page 557)
You are starting analysis for jams only from the AUX Tray.
a. Load paper in the Auxiliary Tray. Set PAPER MENU/SOURCE=AUX andverify PAPER MENU/AUXSIZE. Run a CONFIG PAGE.
b. Inspect the Front Bottom Tray through Front Tray Opening.
Is the Front Bottom Tray raised during printing?
Go to step 14 Go to step 13
Chapter 2. Diagnosing Problems 78
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
13.
OPERATION OF PICK UP SOLENOID (Asm-Index: 6-17, page 559)
a. Remove the EP cartridge. Close the covers, but leave the Aux Tray openb. Run D50 (see “D50 SOL TRAY A (Auxiliary Tray Feed Solenoid)” on
page 277). From the front of the printer watch for the Aux Pick UpSolenoid try to move the cams at both ends of the shaft on the frontbottom tray. Also, listen for the solenoid to pick.
Does the Pick Up Solenoid operate properly?
Go to step 14 Replace orreassemble theFront Bottom Tray(See page 464)
14.
PICK UP ROLL (Asm-Index: 6-9, page 559) and RETARD PAD ASSEMBLY
a. Run another CONFIG PAGE.b. Inspect the transportation of the paper through Front Tray Opening.
Does the Pick Up Roll transport the paper properly without slipping?
Go to step 15 Replace TransportChute Assembly(See page 468)
15.
ROTATION OF PICK UP GEAR (Asm-Index: 6-15, page 559)
a. Run another CONFIG PAGE.b. Inspect the Pick Up Gear through the narrow opening at the left end of the
EP cartridge (is the cartridge installed?).
Does the Pick Up Gear rotate once during each paper feed?
Clean the Pick UpRoll, Retard PadAssembly, and/orTransport ChuteAssembly
Replace orreassemble parts.
16.REGISTRATION SENSOR
Use “D21 SENSOR TEST” on page 261 to test the Registration Sensor.
Does the Registration Sensor function correctly?
Go to step 17 Go to“RegistrationSensor” onpage 172
Chapter 2. Diagnosing Problems 79
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
17.
The paper jams from Tray 1 and the Aux Tray, but the registration sensor isOK.
Do the tests in step 3 again.
Is there still a problem?
Paper feedproblem
Go to “Intermittentor RandomProblems” onpage 133
18.
TRAY 1 SPRINGS
You are starting analysis for Tray 1 pick problems.
Check Tray 1 (refer to instructions in Step 11).
Is the tray OK?
Go to step 19 Replace the tray
19.
FEED SOLENOID (Asm-Index: 4-8, page 555)
a. Run D51 (see “D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid)” onpage 279).
b. Inspect operation of the Feed Solenoid.
Does the Feed Solenoid operate?
Go to step 20 Go to “FeedSolenoid” onpage 155
20.
FEED GEAR and FEED SOLENOIDa. Run a Test Print (see page 252).
b. Inspect the Feed Solenoid to actuate the Feed Gear.
Does the Feed Solenoid properly actuate the Feed Gear?
Unknown pickproblem from Tray1
Replace the FeedSolenoid (Seepage 446)
Chapter 2. Diagnosing Problems 80
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
21.
CAUTION:<2-35> Remove all watches, rings, jewelry, and other articles(such as a necktie) that may catch on printer parts beforeworking in this area.
TURN ROLL ASSEMBLY (Asm-Index: 4-10, page 555) andREAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555)
You are starting analysis for a Tray 1 turn roll problem.
a. Install the Paper Cassette without the Cassette Cover.b. Run a CONFIG PAGE.c. While the paper is transported, inspect the rolls by opening
the Turn Chute Assembly (Asm-Index: 3-5, page 553) at therear of the printer.
Do the rolls turn?
Mechanicalproblem in papertransport
Go to step 22
22.
ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555)
Run D41 (see “D41 CLUTCH TR (Turn Roll Clutch)” on page 269). You shouldhear a clicking sound when the clutch activates.Note: If you have a 500-Sheet Tray 2, you will hear that clutch activate also.Put your finger on the Turn Roll Shaft near the clutch while activating D41 todetermine if the clutch is activating.
Does the Electromagnetic Clutch function correctly?
Go to the laststep of thisdiagnostic.
Go to step 23
23.ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555)
Replace the Electromagnetic Clutch (See page 449).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Replace theFeeder PWB (Seepage 420)
Chapter 2. Diagnosing Problems 81
Table 17. 21 PAPER JAM (continued)
Step Actions and Questions Yes No
24.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 82
22 PAPER JAM
Meaning : Paper has jammed in the duplex unit.
Action : Clear the jam.
Error Code Diagnostic Procedure : “22 PAPER JAM (or 21 PAPER JAM from Duplex)” on page 608.
Chapter 2. Diagnosing Problems 83
23 PAPER JAM
Meaning : There is a paper jam between the Registration Sensor and the Exit Sensor. Can also be caused ifthe paper did not reach the Exit Sensor from the Registration Sensor in the required time.
Action : Clear the jam.Table 18. 23 PAPER JAM
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor
v Registration Clutch Assembly (Asm-Index: 10-9, page 570)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v BTR Assembly (Asm-Index: 6-1, page 559)
v EP Cartridge (Asm-Index: 11-40, page 572)
v Main Gear Assembly (Asm-Index: 10-10, page 570)
v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
v High Harness Assembly (Asm-Index: 6-5, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1. PAPER CONDITIONS
Is the paper loaded in the paper tray wrinkled or damaged?
Replace withfresh, dry paper
Go to step 2
Chapter 2. Diagnosing Problems 84
Table 18. 23 PAPER JAM (continued)
Step Actions and Questions Yes No
2.
PAPER JAM
Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also seeTable 58 on page 293.
Is there any foreign material (such as paper) near the RegistrationActuator?
Remove anyforeign materialNote: Turn theregistration roll byhand to removehard to reachpaper.
Go to step 3
3.
PAPER POSITIONa. If the Duplex Option is installed, remove it.
Note: If paper jams do not occur with the Duplex Option removed, replacethe Duplex Option.
b. Print TEST MENU/CONFIG PAGE until a 23 PAPER JAM occurs.c. Open the Fuser Cover Assembly.d. Open the Fuser Rear Cover (Asm-Index: 8-10, page 564).
e. Inspect the position of paper when the error code 23 PAPER JAM isdisplayed.
Did the paper reach or pass the Exit Actuator (Asm-Index: 8-24, page564)?
The exit sensingmay be bad. Goto step 11.
The paper doesnot reach the exitactuator. Go tostep 4.
4. Did the paper reach the Fuser? Fuser or maingear problem.
Go to step 5
5.
TRANSPORT ASSEMBLY (Asm-Index: 7-1, page 562)
Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) and theRubber Registration Roll (Asm-Index: 7-11, page 562).
Do the Metal Registration Roll and the Rubber Registration Roll rotatesmoothly?
Replace the EPCartridge. If thatdoes not fix theproblem, go tostep 6.
Replace theTransport ChuteAssembly (Seepage 468)
Chapter 2. Diagnosing Problems 85
Table 18. 23 PAPER JAM (continued)
Step Actions and Questions Yes No
6.
REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570)
Inspect paper position when Error Code 23 PAPER JAM is displayed.
Did the front edge of paper pass between the Metal Registration Roll(Asm-Index: 7-10, page 562) and the Rubber Registration Roll(Asm-Index: 7-11, page 562)?
Go to step 8 Go to step 7
7.
REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570)
Use “D43 CLUTCH REG (Registration Clutch)” on page 271 to check theRegistration Clutch Assembly.
Does the Registration Clutch function properly?
Go to step 8 Replace theRegistrationClutch Assembly(See page 495). Ifthe problem stillexists, there is abad MCU PWB orHigh HarnessAssembly.
8.
GEAR RELEASE MECHANISM OF MAIN GEAR ASSEMBLY (Asm-Index:10-10, page 570)
a. Remove the Fuser Assembly (Asm-Index: 8-1, page 564).
b. Open and close the Pop Up Unit.
Does the Gear Release Mechanism sink down when you open the PopUp Unit, and rise up when you close the Pop Up Unit?
Go to step 9 Replace the MainGear Assembly(See page 497)
9.
ROTATION OF BTR ROLL AND EP CARTRIDGE DRUM
Inspect the position of front edge of the paper.
Did the front edge of the paper pass between the BTR and the Drum?
Go to step 10 Replace the BTRAssembly (Seepage 466), EPCartridge, or theTransport ChuteAssembly (Seepage 468)
Chapter 2. Diagnosing Problems 86
Table 18. 23 PAPER JAM (continued)
Step Actions and Questions Yes No
10.
There is a paper transport problem between the Registration Sensor and theFuser Exit Sensor. One of the following parts is bad:v Paper Path (check for obstructions)v Main Gear Assembly (Asm-Index: 10-10, page 570)
v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v BTR Assembly (Asm-Index: 6-1, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
11.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
Replace the Fuser Assembly (See page 487).Note: The Fuser is part of the Usage Kit.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 12
12.
Use “D21 SENSOR TEST” on page 261 to test the Exit Sensor and circuits(you will need to override the fuser cover switch).
Is the sensing OK?
The paperprobably did notreach the sensorin time. Go tostep 5.
Go to step 13
Chapter 2. Diagnosing Problems 87
Table 18. 23 PAPER JAM (continued)
Step Actions and Questions Yes No
13.
The Fuser exit sensing is bad, one of the following parts is bad:v High Harness Assembly (Asm-Index: 6-5, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
14.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 88
24 PAPER JAM
Meaning : There is a paper jam between the Paper Cassette / Auxiliary Tray and the Registration Sensor. Thisoften occurs when another paper jam has not been completely cleared. It can also occur if the paper arrivesat the sensor early due to a premature paper pick.
Note: If you were running a pick/feed diagnostic, D50 SOL TRAY A (Auxiliary Tray Feed Solenoid), D51SOLENOID TRAY1 (Tray 1 Feed Solenoid), D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid), or D53SOLENOID TRAY3 (Tray 3 Feed Solenoid), the 24 PAPER JAM may have occurred because asolenoid was pre-picked.
Action : Remove jammed paper from the paper path. Open and close the top cover.
If this action does not fix the problem, go to Table 19 on page 90.
Chapter 2. Diagnosing Problems 89
Table 19. 24 PAPER JAM
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v Sensor Problems:– Registration Sensor (Asm-Index: 7-6, page 562)
– Registration Actuator (Asm-Index: 7-7, page 562)
v Early Pick from Auxiliary Tray:– Pick Up Solenoid (Asm-Index: 6-17, page 559)
v Early Pick from Tray 1:– Feed Solenoid (Asm-Index: 4-8, page 555)
v 500-Sheet Paper Tray Option Problems:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page
697)
v General:– Feeder PWB (Asm-Index: 3-1, page 553)
– MCU PWB (Asm-Index: 12-8, page 575)
– High Harness Assembly (Asm-Index: 6-5, page 559)
– Feeder Harness (Asm-Index: 3-12, page 553) in Asm-Index: 3-6
– Tray Harness (Asm-Index: 12-17, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1.Paper sizes that are not within specifications can cause paper jams (See“Appendix C. Media Specifications” on page 593).
Is the paper size used within specifications?
Go to step 2 Replace withpaper withinspecifications
Chapter 2. Diagnosing Problems 90
Table 19. 24 PAPER JAM (continued)
Step Actions and Questions Yes No
2.
Switch off printer power, and remove paper from all trays, and then switch onprinter power.
Does the error code appear immediately after switching ON the MainPower?
Go to step 3 Go to step 5
3.
PAPER JAM
Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also seeTable 58 on page 293.
Is there any foreign material (such as paper) touching the RegistrationActuator?
Remove foreignmaterialNote: Turn theregistration roll byhand to removehard to reachpaper.
Return to step 2.
Go to step 4
4.
REGISTRATION SENSOR (Asm-Index: 7-6, page 562)
Use the “D21 SENSOR TEST” on page 261 to check the function of theRegistration Sensor.
Does the Registration Sensor function correctly?
Possibleintermittentregistrationsensing problem,or a dirty sensor.
Go to“RegistrationSensor” onpage 172
5.
DUPLEX UNIT
Does the problem appear only when using the Duplex Unit?
Go to“Appendix E.Duplex UnitOption” onpage 604
Go to step 6
Chapter 2. Diagnosing Problems 91
Table 19. 24 PAPER JAM (continued)
Step Actions and Questions Yes No
6.
PREMATURE PAPER PICKa. Switch off printer power.b. Add paper to all sources, including the Auxiliary tray.c. Switch on printer power.
Does the error code appear immediately after switching ON the MainPower?
Go to step 7 The error mayhave beencaused by paperthat is now gone.Run TESTMENU/CONFIGPAGE to see ifanother occurs.
7.Is there paper in the paper path? Go to step 8 Go to
“RegistrationSensor” onpage 172
8.Determine which paper sources have the premature paper pick.
Is the problem only with the Auxiliary tray?
Go to “Pick UpSolenoid(Auxiliary Tray)”on page 170
Go to step 9
9.
Does the problem appear when using Tray 2 or 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661 or“Appendix H.2000-Sheet InputDrawer Option” onpage 703
Go to step 10
10. There is a premature feed problem with Tray 1. Go to “Feed Solenoid” onpage 155.
Chapter 2. Diagnosing Problems 92
Table 19. 24 PAPER JAM (continued)
Step Actions and Questions Yes No
11.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 93
26 PAPER JAM
Meaning : Paper has jammed in the 2000-Sheet Input Drawer exit area.
Action : Remove jammed paper from the paper path. Open and close the top cover.
Error Code Diagnostic Procedure : “26 PAPER JAM” on page 711.
27 PAPER ERROR <source>
Meaning : There is a conflict between the size of paper the printer senses in a Cassette (Tray) and Auxiliarytray and the size of paper that is loaded. This can happen when the printer detects paper that seems too long(including multi-sheet feeds) or too short. This usually occurs because the user fed a size/orientation in theAuxiliary Tray that did not match the PAPER MENU/ AUXSIZE setting.
If CONFIG MENU/AUTOCONTINU=ON, the error message only displays for a short time before doing an″automatic continue″.
Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds. Makesure paper is correctly loaded in the tray and the end guides in the tray are properly set. For the auxiliary tray,verify the AUXSIZE setting on the Paper Menu. You may need to open and close the top cover to clear thecondition.
If this action does not fix the problem, go to Table 20 on page 95.
Chapter 2. Diagnosing Problems 94
Table 20. 27 PAPER ERROR <source>
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Problems with Tray 1 size sensing:– Feeder PWB (Asm-Index: 3-1, page 553)
– Cassette Guide Assembly L (Asm-Index: 3-6, page 553), includingharness
– Paper Cassette (Asm: 2, page 550)
– Tray Harness (Asm-Index: 12-17, page 575)
v Problems with 500-Sheet Paper Tray option size sensing:– Feeder Assembly (Asm-Index: 20-1, page 697)
v General:– MCU PWB (Asm-Index: 12-8, page 575)
v Slow paper feeding:– Transport Chute Assembly (Asm-Index: 6-2, page 559)
1. Does the problem appear when printing from Tray 1 or a Tray 2 or a Tray3 option?
Go to step 5 Go to step 2
2. Does the error message appear when you feed from the Multi SheetInserter (Auxiliary tray)?
Go to step 3 Go to step 4
Chapter 2. Diagnosing Problems 95
Table 20. 27 PAPER ERROR <source> (continued)
Step Actions and Questions Yes No
3.
AUXSIZE SETTING
Check the PAPER MENU/AUXSIZE setting. must match the paper size andorientation (LEF=Long Edge Feed, SEF=Short Edge Feed) of the paper in theAuxiliary tray.
Is the setting OK?
There may be aproblem causingslow paperfeeding from theAuxiliary tray.
Correct theAUXSIZE setting
4.
2000-SHEET INPUT
Does the problem appear when printing from the 2000-Sheet Paper TrayOption?
Go to“Appendix H.2000-Sheet InputDrawer Option” onpage 703
There is aproblem with theEnvelope optionor an intermittentproblem.
5.
PAPER LOADING
Check each paper tray and the paper guide adjustments.
Does each tray have the size guides adjusted to match the loadedpaper?
Go to step 6 Adjust the paperguides
6.
TRAY SIZE SENSINGa. Print TEST MENU/CONFIG PAGE.b. If an error occurs, press CONTINUE.c. On the CONFIG PAGE, under ″Auto Sensed Paper″, compare the sizes
listed to the paper sizes in the trays.
Do the sizes match for all trays?
Go to step 7 Go to “Paper SizeSwitch -500-Sheet PaperTrays” onpage 165
7.
Paper loading and size sensing seem OK. If the error no longer occurs, it wasprobably caused by a multiple sheet feed. If the error still occurs, there maybe a mechanical problem causing slow paper feeding.
Chapter 2. Diagnosing Problems 96
Table 20. 27 PAPER ERROR <source> (continued)
Step Actions and Questions Yes No
8.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 97
29 OUTPUT FULL
Meaning : The output bin is full.
Without a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index:8-8, page 564) in the Fuser Assembly. When a duplex option is installed, the printer monitors the Duplex StackActuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator.
When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed onthe operator panel. The printer continues to print a few more pages to clear the paper path before it stops.The 29 OUTPUT FULL message remains until the signals indicate that the paper stack has been removed.
Notes:
1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printerstops after the paper path clears.
2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the user can remove the duplexunit and continue to print simplex jobs.
Action : Remove the output from the bin.
If this action does not fix the problem, go to Table 21.Table 21. 29 OUTPUT FULL
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564), includes Full Stack Sensor
v MCU PWB (Asm-Index: 12-8, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
v If the error only occurs with the Duplex Option, see “29 OUTPUT FULL,with Duplex Installed” on page 610.
Chapter 2. Diagnosing Problems 98
Table 21. 29 OUTPUT FULL (continued)
Step Actions and Questions Yes No
1.PAPER STACK
Is there a paper stack on the Pop Up Cover Assembly close to the FullStack Actuator (Asm-Index: 8-8, page 564)?
Remove paperstack
Go to step 2
2.PAPER CONDITIONS
Is the paper curled?
Replace withfresh dry paper,and go to step 3
Go to step 3
3.
DUPLEX UNIT
Is the printer equipped with a Duplex Unit?
The Full StackSensor on theFuser is disabled.Go to “29OUTPUT FULL,with DuplexInstalled” onpage 610.
Go to step 4
4.
FULL STACK ACTUATOR and SENSOR (Asm-Index: 8-8 and 8-7, page564)
a. Open the Fuser Cover Assembly.b. Push up and then release the Full Stack Actuator.c. Check the actuator and the sensor for correct operation.
Are the actuator and the sensor OK?
Go to step 5 Replace theFuser Assembly(See page 487)
5.
FULL STACK SENSOR (Asm-Index: 8-7, page 564)
a. Use “D21 SENSOR TEST” on page 261 to check the Full Stack Sensor.
b. Press and release the Full Stack Actuator (Asm-Index: 8-8, page 564).
Is the sensor OK?
Possibleintermittent orrandom problems,see page 133
Go to step 6
Chapter 2. Diagnosing Problems 99
Table 21. 29 OUTPUT FULL (continued)
Step Actions and Questions Yes No
6.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
Replace the Fuser Assembly (See page 487).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 7
7.
High Harness Assembly (Asm-Index: 6-5, page 559)
v Remove the Controller Assembly (See page 535).
v Disconnect P/J14 from the MCU.v Check the following for continuity:
– J14-8 <=> J142-A1 (at Fuser connection)– J14-7 <=> J142-A2– J14-6 <=> J142-A3
Is there continuity?
Replace the MCU(See page 526)
Replace the HighHarnessAssembly(Asm-Index: 6-5,page 559).Note: Use theremovalprocedure for theTransport ChuteAssembly (Seepage 468)
8.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 100
30 MEMORY OVERFLOW
Meaning : Memory overflow. The printer has received more data than it can fit into its memory. This canhappen when the printer receives too many soft fonts, macros, or complex graphics.
Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds.Otherwise, press the Continue key. Check the current page for errors.
31 MEMORY ALLOC ERROR
Meaning : The printer cannot allocate the memory required to print a job.
Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds.Otherwise, press the Continue key. Check the current page for errors.
32 PRINT OVERRUN
Meaning : A page is too complex to print at the current resolution.
Action : Do one of the following:v If QUALITY is set to 1200, change it to something else (such as 600) and resubmit the job. Use your printer
driver or the Config Menu. The driver setting overrides the menu setting.v If you are feeding paper long-edge first, change it to short-edge first.v Have the customer add more memory.
40 MEMORY OPTION ERROR
Meaning : A SIMM module is not properly seated in its slot or is defective.
Action : Turn off the printer. Remove the controller card. Reseat the SIMM module. If the message recurs afteryou restart the printer, install a new SIMM module.
Chapter 2. Diagnosing Problems 101
41 NETWORK OPTION ERROR
Meaning : The printer detected a network interface card in the top slot, but the card is not communicating.
Action : Make sure the network interface card is properly installed and restart the printer. If the same messagerecurs, move the network interface card to the bottom slot and restart the printer. If the message 42NETWORK OPTION ERROR occurs, replace the network interface card. If no message occurs with thenetwork interface card in the bottom slot, replace the Controller.
Remove the network interface card from the printer if you want to print a configuration page or print from theparallel port.
42 NETWORK OPTION ERROR
Meaning : The printer detected a network interface card in the bottom slot, but the card is not communicating.
Action : Make sure the network interface card is properly installed and restart the printer. If the same messagerecurs, move the network interface card to the top slot and restart the printer. If the message 41 NETWORKOPTION ERROR occurs, replace the network interface card. If no message occurs with the network interfacecard in the top slot, replace the Controller.
Remove the network interface card from the printer if you want to print a configuration page or print from theparallel port.
Chapter 2. Diagnosing Problems 102
43 PS OPTION ERROR
Meaning : The printer has detected a problem with the PostScript section of the Controller SIMM.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset asfollows (this resets all values in printer NVRAM to factory defaults):1. Print a configuration page “Configuration Page” on page 250.
2. Switch off printer power.3. Do the following:
For the LTR (letter) paper group:Press and hold the Online key while switching on printer power. COLD RESET LTR appears in themessage display.For the A4 paper group:Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in themessage display.
If the error recurs, replace the Controller SIMM (See “Controller PWB SIMM” on page 539).
If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
44 IPDS OPTION ERROR
Meaning : The printer has detected a problem in the IPDS SIMM.
Action : Reinstall the IPDS SIMM. If the message recurs, replace the IPDS SIMM (See “Controller PWBSIMM” on page 539). If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
Chapter 2. Diagnosing Problems 103
45 OPTION ERROR
Meaning : The printer has detected a problem with a SIMM (probably the IPDS SIMM).
Action : Reinstall all SIMMs. If the message recurs, replace the IPDS SIMM (See “Controller PWB SIMM” onpage 539). If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
46 NETWORK OPTION ERROR
Meaning : The printer has detected that two of the same network interface cards have been installed.
Action : Remove one of the cards.
Chapter 2. Diagnosing Problems 104
50 ERROR CALL FOR SERVICE
Meaning : The printer detected a fuser problem.
Action : Turn off the printer for fifteen minutes and then turn on the printer.
If this action does not fix the problem, go to Table 22.Table 22. 50 ERROR CALL FOR SERVICE
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
1.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
a. Install a new Fuser Assembly (See page 487).
b. Switch ON the main power. Time how long it takes forREADY or 50 ERROR CALL FOR SERVICE to display.
Does READY appear?
Verify the fix. Alsoverify that theproblem jobprints.
If 50 ERRORCALL FORSERVICE app-eared, go to step2.
For other errorsor messages,return to“Chapter 1.Getting Started”on page 25.
2.Did 50 ERROR CALL FOR SERVICE appear within the first minute? There is a fuser
sensing problem.Go to step 3.
There is a fuserheating problem.Go to step 4.
Chapter 2. Diagnosing Problems 105
Table 22. 50 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
3.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)
a. Disconnect P/J14 from the MCU PWB (Asm-Index: 12-8,page 575).
b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564).This will expose J142.
c. Check for the continuity of each wire between:v J14-5 <=> J142-A4 (TEMP)v J14-4 <=> J142-B1 (SG)
Is there continuity between J14 <=> J142?
Replace the MCU(See page 526 or529)
Replace the HighHarnessAssembly
4.
LVPS HARNESS (Asm-Index: 12-14, page 575)
a. Disconnect P/J121 from the LVPS Assembly (Asm-Index: 12-4, page 575)and P/J11 from the MCU PWB (Asm-Index: 12-8, page 575).
b. Check for the continuity of each wire between J11 <=> J121.
Is there continuity between J11 <=> J121?
Go to step 5 Replace the LVPSHarness
Chapter 2. Diagnosing Problems 106
Table 22. 50 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
5.
HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)
a. Disconnect P/J124 from the LVPS Assembly (Asm-Index: 12-4, page 575).
b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). This will exposeJ142.
c. Activate the Fuser Cover Switch, and check for continuity between:v P/J124-3 <=> P/J142-3 (AC N)v P/J124-1 <=> P/J142-1 (AC L)
Is there continuity between J124 <=> J142?
Go to step 6 Replace theFuser CoverSwitch (See page516) or the wiresand connector, orthe High HarnessAssembly (Seepage 521).
6.LVPS ASSEMBLY (Asm-Index: 12-4, page 575)
Replace the LVPS (See page 521).
Problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Replace the MCU(See page 526 or529)
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 107
51 ERROR CALL FOR SERVICE
Meaning : There is a problem with the ROS (Printhead) Assembly.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, go to “Appendix D.Technical Support” on page 602.
Chapter 2. Diagnosing Problems 108
52 ERROR CALL FOR SERVICE
Meaning : There is a problem with the ROS (Printhead) Assembly.
Action : Power off the printer, wait twenty seconds, then power on.
If this action does not fix the problem, go to Table 23.Table 23. 52 ERROR CALL FOR SERVICE
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v POP-UP/ROS Assembly (Asm-Index: 11-20, page 572)
v CRU Sensor Assembly (Asm-Index: 11-15, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1.
CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)Note: The CRU Sensor Assembly has a switch to detect the presence of theEP cartridge and an LD switch that disables the ROS Laser Diode when thecartridge is removed.
a. Run “D21 SENSOR TEST” on page 261 to test the CRU sensor andcircuits.Note: Test D21 does not test the LD switch.
b. Open and close the Pop Up Unit.
Is sensing OK?
Go to step 2 Replace the CRUSensor Assembly,which includesthe Harness (Seepage 503)
2.Remove the controller, and verify that connector P/J12 (ROS) at the MCU isOK.
Are the connectors OK?
Go to step 3 Repair as needed
Chapter 2. Diagnosing Problems 109
Table 23. 52 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
3.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
LASER DIODE POWERa. Unplug P/J12.b. Install the EP Cartridge (Asm-Index: 11-40, page 572).
c. Close the Pop Up Unit.d. Check the voltage between P12-7 (5VDC-LD)<=> P12-6
(SG) on the MCU PWB (Asm-Index: 12-8, page 575).
Is there +5 VDC between P12-7 <=> P12-6?
Go to step 4 Replace the MCUPWB (See page526 or 529), orthe LVPSAssembly (Seepage 521).
4.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
LASER DIODE POWER SUPPLY OF ROS ASSEMBLY(Asm-Index: 11-20, page 572)
Check the voltage between P12-2 <=> P12-6.
Is there 5VDC between P12-2 <=> P12-6?
Go to step 6 Go to step 5
Chapter 2. Diagnosing Problems 110
Table 23. 52 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
5.
CONTINUITY ON MCU PWB
Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).
Check for the continuity between P11-2 <=> P12-1.
Is there continuity between P11-2 <=> P12-1?
Replace the LVPSAssembly (Seepage 521), or theLVPS Harness.
Replace the MCUPWB (See page526 or 529)
6.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
SOS POWER SUPPLY OF ROS ASSEMBLY (Asm-Index:11-20, page 572)
a. Disconnect P/J15.b. Check the voltage between P/J12-10 <=> P/J12-8.
Is there 5VDC between P/J12-10 <=> P/J12-8?
Go to step 7 LVPS problem, goto “LVPS” onpage 163.
Chapter 2. Diagnosing Problems 111
Table 23. 52 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
7.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
SCANNER ASSEMBLY POWER SUPPLY
Check the voltage between P12-15 <=> P12-14.
Is there 24VDC between P12-15 <=> P12-14?
Go to step 9 Go to step 8
8.
CONTINUITY ON MCU PWBa. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).
b. Check for the continuity between P12-15 <=> P21-1.
Is there continuity between P12-15 <=> P21-1?
Go to “24V PowerSupply to MCU”on page 144
Replace the MCUPWB (See page526 or 529)
Chapter 2. Diagnosing Problems 112
Table 23. 52 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
9.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
SCANNER MOTOR ON SIGNALa. Switch OFF the Main Power.b. Leave P/J15 disconnected.c. As you switch on the power in the next step, observe the
voltage between P/J12-13 <=> P/J12-14.d. Switch ON the Main Power.
Is there 4.1VDC between P/J12-13 <=> P/J12-14 when youswitch on the Main Power?
Go to step 10 Replace the MCUPWB (See page526 or 529)
10.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 113
53 ERROR CALL FOR SERVICE
Meaning : There is a problem with the Main Motor.
Action : Power off the printer, wait twenty seconds, then power on.
If this action does not fix the problem, go to Table 24.Table 24. 53 ERROR CALL FOR SERVICE
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Main Motor (Asm-Index: 10-6, page 570)
v MCU PWB (Asm-Index: 12-8, page 575)
v Main Gear Assembly (Asm-Index: 10-10, page 570)
v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
v EP Cartridge (Asm-Index: 11-40, page 572)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Feeder Assembly (Asm-Index: 20-1, page 697)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v Rear Roll Assembly (Asm-Index: 4-11, page 555)
v Turn Roll Assembly (Asm-Index: 4-10, page 555)
v Feed Shaft Assembly (Asm-Index: 4-2, page 555)
Note: The Main Motor runs when the printer power is switched on, and stopsafter the fuser reaches operating temperature.
Chapter 2. Diagnosing Problems 114
Table 24. 53 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
1.
MAIN MOTOR START (Asm-Index: 10-6, page 570)
a. Switch off printer power.b. Remove the Controller Assembly (See page 535).
c. Close all interlocksd. Switch on printer power.
Does the Main Motor start or try to start?
Go to step 2 Go to step 12
2.
MAIN MOTOR (Asm-Index: 10-6, page 570)
Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually. The magnets in the Main Motor will cause pulsing resistance.
Does the Main Motor rotate smoothly without binding?
Go to step 3 Go to step 7
3.
TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559)
a. Open the Pop Up Unit.b. Remove the EP Cartridge (Asm-Index: 11-40, page 572).
c. Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) andRubber Registration Roll (Asm-Index: 7-11, page 562) manually, turning thegears at the end of the metal roll.
Do the Metal Registration Roll and Rubber Registration Roll rotatesmoothly?
Go to step 4 Replace theTransport ChuteAssembly (Seepage 468)
4.
REAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555) and TURN ROLLASSEMBLY (Asm-Index: 4-10, page 555)
a. Open the Turn Chute Assembly.b. Rotate the Rear Roll and the Turn Roll manually.
Do the Rear Roll and the Turn Roll rotate smoothly?
Go to step 5 Replace the RearRoll Assembly(See page 453) orthe Turn RollAssembly (Seepage 451)
Chapter 2. Diagnosing Problems 115
Table 24. 53 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
5.
PICK UP ROLL ASSEMBLY (Asm-Index: 6-8, page 559)
a. Press down the Armature of the Pick Up Solenoid (Asm-Index: 6-17, page559).
b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually.
Does the Pick Up Roll Assembly rotate smoothly?
Go to step 6 Replace theTransport ChuteAssembly (Seepage 468)
6.
FEED SHAFT ASSEMBLY (Asm-Index: 4-2, page 555)
a. Press down the armature of the Feed Solenoid (Asm-Index: 4-8, page555).Note: The Feed Solenoid is located behind the MCU PWB, near the lowerleft corner.
b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually.
c. Inspect the rotation of the Feed Gear (Asm-Index: 4-5, page 555).
Does the Feed Gear rotate smoothly?
Go to step 12 Replace Gears,etc. which maydisturb therotation (Seepage 438, 442, or446)
7.
EP CARTRIDGE (Asm-Index: 11-40, page 572)
a. Remove EP Cartridge.b. Rotate the rotor of Main Motor (Asm-Index: 10-6, page 570) clockwise
manually.
Does the rotor of Main Motor rotate smoothly?
Replace the EPCartridge(Asm-Index:11-40, page 572)
Go to step 8
Chapter 2. Diagnosing Problems 116
Table 24. 53 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
8.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
a. Remove the Fuser Assembly (See page 487).
b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page570) clockwise manually.
Does the rotor of the Main Motor rotate smoothly?
Replace theFuser Assembly(See page 487)
Go to step 9
9.
FEEDER ASSEMBLY (Asm-Index: 20-1, page 697)
a. Remove the Out Idler Gear (Asm-Index: 4-16, page 555).
b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually.
Does the rotor of the Main Motor rotate smoothly?
Replace theFeeder Assembly(See page 666)
Go to step 10
10.
PAPER HANDLING GEAR ASSEMBLY (Asm-Index: 10-7, page 570)
a. Remove the Paper Handling Gear Assembly (See page 492).
b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570).
Does the rotor of the Main Motor rotate smoothly?
Replace thePaper HandlingGear Assembly(See page 492).
Go to step 11
11.
MAIN MOTOR (Asm-Index: 10-6, page 570)
a. Remove the Main Motor from the printer frame (See page 489).
b. Rotate the rotor of the Main Motor.
Does the rotor of the Main Motor rotate smoothly?
Replace the MainGear Assembly(Asm-Index:10-10, page 570).
Replace the MainMotor (See page489).
Chapter 2. Diagnosing Problems 117
Table 24. 53 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
12.
MAIN MOTOR HARNESSa. Disconnect P/J16 from the MCU PWB (Asm-Index: 12-8, page 575).
b. Check the resistance between J16-1 <=> J16-2.
Is there approximately 14 K ohms between J16-1 <=> J16-2?
Replace the MainMotor (See page489), or the MCUPWB (See page526 or 529)
Replace the MainMotor (See page489)
13.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 118
54 ERROR CALL FOR SERVICE
Meaning : The printer has detected a problem in the duplex unit.
Action : Make sure the duplex unit is installed correctly. If the problem continues, suspect the followingcomponents:v Duplex Unit (Asm-Index: 30-1, page 652)
v Controller PWB (Asm-Index: 13-6, page 578)
v MCU PWB(Asm-Index: 12-8, page 578)
Chapter 2. Diagnosing Problems 119
55 ERROR CALL FOR SERVICE
Meaning : The Fan is not rotating. The Fan rotates at Low Speed when printer power is switched on. The Fanrotates at High Speed when the Main Motor is switched on.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs.
If this action does not fix the problem, go to Table 25.Table 25. 55 ERROR CALL FOR SERVICE
Step Actions and Questions Yes No
1.
SUSPECT COMPONENTSv Fan (Asm-Index: 12-3, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
Inspect the fan. Is it OK?
Go to step 2 Replace the Fan(See page 518)
2.
FAN (Asm-Index: 12-3, page 575)
Replace the Fan (See page 518).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
See “MCU ⇔LVPS ⇔INTERLOCKSWITCH andFANs” onpage 311, or runD23 (see “D23TEST FAN” onpage 267).
Chapter 2. Diagnosing Problems 120
Table 25. 55 ERROR CALL FOR SERVICE (continued)
Step Actions and Questions Yes No
3.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 121
56 ERROR CALL FOR SERVICE
Meaning : There is problem with NVRAM in the MCU.
Action : Power off the printer, wait twenty seconds, then power on.
If this action does not fix the problem, go to Table 26.Table 26. 56 ERROR CALL FOR SERVICE
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v MCU PWB (Asm-Index: 12-8, page 575)
1.
Switch the printer power off, then on. If using Letter size paper, press ONLINEduring printer power-up. If using A4 size paper, press CANCEL during printerpower-up.Note: If the printer powers on without error, print a CONFIG PAGE.
Does the printer become READY?
Problem fixed, orpossibleintermittent orrandom problems(See page 133)
Go to step 2
2. Does the 56 ERROR CALL FOR SERVICE appear?Replace the MCU(See page 526)
Go to “Chapter 1.Getting Started”on page 25
3.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 122
61 ERROR CALL FOR SERVICE
Meaning : The printer has detected an error in the Controller SIMM checksum.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset asfollows (this resets all values in printer NVRAM to factory defaults):1. Print a configuration page “Configuration Page” on page 250.
2. Switch off printer power.3. Do the following:
For the LTR (letter) paper group:Press and hold the Online key while switching on printer power. COLD RESET LTR appears in themessage display.For the A4 paper group:Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in themessage display.
If the error recurs, replace the Controller SIMM (See “Controller PWB SIMM” on page 539).
If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
62 ERROR CALL FOR SERVICE
Meaning : The printer has detected an error in the DRAM.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs.
If the message recurs, replace the DRAM SIMM (See “Controller PWB SIMM” on page 539).
If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
Chapter 2. Diagnosing Problems 123
63 ERROR CALL FOR SERVICE
Meaning : The printer has detected an error in the NVRAM (EEPROM).
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset asfollows (this resets all values in printer NVRAM to factory defaults):1. Print a configuration page “Configuration Page” on page 250.
2. Switch off printer power.3. Do the following:
For the LTR (letter) paper group:Press and hold the Online key while switching on printer power. COLD RESET LTR appears in themessage display.For the A4 paper group:Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in themessage display.
If the error recurs, replace the Controller SIMM (See “Controller PWB SIMM” on page 539).
If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).
71 DISK ERROR
Meaning : The printer has detected a problem with the hard drive.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.
72 DISK ERROR
Meaning : The printer has detected a problem with the hard drive.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.
Chapter 2. Diagnosing Problems 124
73 DISK ERROR
Meaning : The printer has detected a problem with the hard drive.
Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, install a new hard drive.
80 ADD MEMORY FOR IPDS
Meaning : The printer requires more memory before it can process IPDS jobs.
Action : Have the customer install more memory.
80 ADD MEMORY FOR PAGES, ESC/P
Meaning : The printer requires more memory before it can process PAGES and ESC/P jobs
Action : Have the customer install more memory.
81 INSUFFICIENT MEMORY FOR IPDS
Meaning : The printer does not have enough memory to process IPDS jobs.
Action : Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the errorrecurs, the customer may need to install more memory.
81 INSUFFICIENT MEMORY FOR PAGES
Meaning : The printer does not have enough memory available to process PAGES, ESC/P jobs.
Action : Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the errorrecurs, the customer may need to install more memory.
Chapter 2. Diagnosing Problems 125
82 HOST TIMEOUT
Meaning : The coax network interface card has sent an Intervention Required message to the host. This erroroccurs when (a) the printer is OFFLINE for longer than the HLD TMEOUT setting in the Coax Setup Menu, or(b) the printer has been in an intervention required state (such as out of paper) for longer than the IRQTMEOUT setting.
Action : Solve the problem that caused the message (for example, press the Online key to put the printeronline, or add paper). To disable this error message, set the HLD TMEOUT and IRQ TMEOUT values in theCoax Setup Menu to 0.
83 CX SEND STATE
Meaning : Your coax host has placed your printer in “Send State” and is waiting for the printer to return a PAsignal.
Action : Press the Continue key to clear the message. (You may need to press the key more than once.)Then do the following to send the PA signal.1. Press the Online key to take the printer offline.2. Press the Menu key until you see the Coax SCS Menu.3. Press the Item key until you see PA1 or PA2 (whichever signal you want to send).4. Press the Enter key to send the signal.5. Press the Online key to resume printing.
84 NO FONT SIMM FOR PAGES, ESC/P
Meaning : The printer has detected that Japanese Heisei font SIMM is not installed.
Action : Power off the printer, install a Japanese Heisei font SIMM, and then power on the printer.
Chapter 2. Diagnosing Problems 126
Printer Problems without Error CodesFuse or Power Problem
The fan does not rotate, the motors never turn on, and the operator panel is blank. The printer does notfunction.
Chapter 2. Diagnosing Problems 127
Table 27. Fuse or Power Problem
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v LVPS Assembly (Asm-Index: 12-4, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
v Interlock Switch (Asm-Index: 12-1, page 575)
v Fan (Asm-Index: 12-3, page 575)
v Console Assembly (Asm-Index: 1-18, page 548)
v ROS Assembly (Asm-Index: 11-20, page 572)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v MSI No Paper Sensor (Asm-Index: 5-9, page 557)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v HVPS (Asm-Index: 12-11, page 575)
v Main Motor (Asm-Index: 10-6, page 570)
v CRU Sensor Assembly (Asm-Index: 11-15, page 572)
v Toner Sensor Assembly (Asm-Index: 5-13, page 557)
v Feeder PWB (Asm-Index: 3-1, page 553)
v Feed Solenoid (Asm-Index: 4-8, page 555)
v Electromagnetic Clutch (Asm-Index: 4-9, page 555)
v Cassette No Paper Sensor (Asm-Index: 3-11, page 553)
Chapter 2. Diagnosing Problems 128
Table 27. Fuse or Power Problem (continued)
Step Actions and Questions Yes No
1.
AC POWER CORD
Plug the AC Power Cord into the back of the printer, and the other end into anAC wall outlet.Note: If there is a 2000-Sheet Paper Tray Option installed, there are twopower cords and two power switches. One cord connects the option to thewall outlet, and the other connects the option to the printer. AC power ispresent at both machines even when both power switches are turned off.
Switch on the power switches.
Does the problem still exist?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.Note: If there is adifferent symptom,go to “Chapter 1.Getting Started”on page 25.
2.
AC POWER
Check the voltage at the AC wall outlet. The acceptable voltage ranges are:v Low voltage: 100–127 V acv High voltage: 220–240 V ac
Is the measured voltage OK?
Go to step 3 Notify customer ortheir electrician.
3.
CONTROLLERa. Remove the Controller Assembly (See page 535).
b. Switch ON the Main Power.c. Observe the Fan (Asm-Index: 12-3, page 575).
Does the Fan rotate?
There is aproblem with thecontroller, acontroller option,or the console.
Go to step 4
Chapter 2. Diagnosing Problems 129
Table 27. Fuse or Power Problem (continued)
Step Actions and Questions Yes No
4.
LVPS OR LVPS FUSE (Asm-Index: 12-4, page 575)
a. Remove the LVPS Assembly (See page 521).
b. Remove the fuse, located near the power switch.c. Check the continuity of the fuse.
Is the fuse OK?
Replace the LVPSAssembly (Seepage 521)
Go to step 5
5.
LVPS FUSE
Blown fuse. This can be caused by a defective LVPS, a defective FRUconnected to the LVPS, or an overcurrent condition that no longer exists.a. Install a new fuse (10A). If a fuse is not available, install a new LVPS.b. Disconnect P/J11 from the MCU Assembly. Ensure that the fan is
connected to the LVPS (P/J122).
Does the Fan rotate?
The fuse is OK.There may beanother problemthat blew theoriginal fuse. Goto step 6.
Go to step 7
6.
MCU CIRCUITSa. Connect P/J11.b. Switch on the printer power.
Does the Fan rotate?
The blown fusewas the problem.If the fuse blowsagain later, go tostep 7.
The fuse blewagain. One of theMCU loads iscausing aproblem. Obtainmore fuses, anddiagnose bysequentiallyconnecting theconnectors listedin step 7.
Chapter 2. Diagnosing Problems 130
Table 27. Fuse or Power Problem (continued)
Step Actions and Questions Yes No
7.
LVPS (Asm-Index: 12-4, page 575)
Replace the LVPS Assembly (See page 521)
Other components that can blow the fuse:
v At the LVPS:– P/J122: to the fan
v At the MCU:– P/J11: to the LVPS (and all of the following)– P/J12: to the ROS Assembly– P/J13: to the Registration Clutch, Registration Sensor, No Paper Sensor
and Pick Up Solenoid– P/J14: to the Fuser Assembly– P/J15: to the HVPS– P/J16: to the Main Motor– P/J18: to the Interface PWB or to Fuser Cover Switch– P/J19: to the Console Panel– P/J20: to the Feeder PWB– P/J31: to the Controller Assembly– Controller, Controller option, or console.
Chapter 2. Diagnosing Problems 131
Table 27. Fuse or Power Problem (continued)
Step Actions and Questions Yes No
8.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 132
Intermittent or Random Problems
Gather as much information as possible (see “Defining the Problem” on page 26). Closely inspect thesuspected area, assembly, or part.
You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post an errorcode.
Check the following:
1. Is the printer plugged into a recommended AC outlet?2. Is the AC power at the outlet within specifications?3. Is the AC power cord connected to the printer?4. Is the AC power cord in good condition; not frayed or broken?5. Is the printer grounded through the AC outlet?6. Is recommended paper stock used in the printer?7. Is the printer in an area where the temperature and humidity are moderate and stable?8. Is the printer in an area that is free of dust?9. Is the printer in an area away from water outlets, steamers, electric heaters, volatile gases, or open
flames?10. Is the printer shielded from the direct rays of the sun?11. Does the printer have recommended space around all sides for ventilation?12. Is the printer on a level and stable surface?13. Does the customer use the printer as instructed in the customer documentation?14. Are consumables, such as the EP Cartridge, replaced at recommended intervals?
If you suspect a controller problem, see “Operator Panel, Controller, and Power Problems” on page 135.
Chapter 2. Diagnosing Problems 133
If you do not resolve the problem, return to “Diagnostic Quick Path” on page 28 and define the problem againor call 1–800–358–6661 for technical support.
If you exchange a part and the problem is not fixed, reinstall the original part.
Check the following:
v Disconnect and reseat connectors in the associated area.v Check for loose, worn, or broken connectors and cables.v Check the environment, such as ambient temperature and humidity.v Check for RF noise such as a radio or TV transmitter.
Chapter 2. Diagnosing Problems 134
Operator Panel, Controller, and Power Problems
Use this diagnostic to solve problems which involve a blank or inoperative operator panel, light or darkrectangles displayed in operator panel, and power problems.Table 28. Operator Panel, Controller, and Power Problems
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v DRAM SIMM (Asm-Index: 100-14∼17, page 585)
v Controller SIMM (Asm-Index: 100-4, page 585)
v Controller PWB (Asm-Index: 13-6, page 578)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
Chapter 2. Diagnosing Problems 135
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
The following should happen at a normal power-up (no network cards, noerrors):
1. IBM INFOPRINT 20 displays soon after the power is switched on.2. The fan turns at low speed.3. The motor turns, causing the exit rolls to move (whenever the motor
turns, the fan runs at high speed).4. All LEDs momentarily turn on and WARMING UP... displays after
approximately 12 seconds.5. The motor stops.6. WARMING UP... continues to display until the fuser warms up (can last
longer than 1 minute if the printer is cold).7. The ONLINE LED blinks.8. After the fuser warms up, the ONLINE LED stays on and READY
displays on the LCD (if a NIC card is installed, I/O INITIALIZING maydisplay for several minutes).
9. Pressing the ONLINE key causes the printer to go off-line. (OFFLINEdisplays on the LED and the ONLINE LED is off.)
10. Menu/item/value keys allow menu navigation.
Note: The Controller must have at least 1 DRAM memory SIMM installed (inthe group of 3 sockets). Since there is no DRAM built into the controller, theController cannot operate without a DRAM SIMM. The symptom with noDRAM is light, solid rectangles on the top line of the display. After severalminutes, unrequested blank pages, or pages with black stripes may print.
Chapter 2. Diagnosing Problems 136
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
1.
Switch on the printer power and wait 5 minutes to ensure that the symptomdoes not change. Look for light, solid rectangles on the top line of the display.These rectangles may be very light; switch off printer power and compare toensure that you do have these rectangles when the printer is switched on.
Is the symptom solid rectangles on the top line of the display?
Go to step 2 Go to step 6
2.
SIMMsa. Reseat the Controller SIMM (OS, PCL, and PS).b. Reseat 1 DRAM SIMM.c. Remove the Controller options, if installed (second DRAM SIMM, third
DRAM SIMM, IPDS SIMM, flash memory SIMM, and the hard drive).
Is the problem fixed?
Reinstall theController optionSIMMS, one at atime, to determinewhich fails.
Go to step 3
3.
DRAM SIMM
Move the DRAM SIMM to another socket within the group of 3 sockets.
Is the problem fixed?
If the userrequires 3 DRAMsockets, replacethe ControllerPWB (See“Controller PWB”on page 537).
Go to step 4
4.If the printer had only 1 DRAM SIMM, replace the SIMM (see “Controller PWBSIMM” on page 539).
Is the problem fixed?
The DRAM SIMMwas bad
Go to step 5
Chapter 2. Diagnosing Problems 137
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
5.
Replace the Controller SIMM (See “Controller PWB SIMM” on page 539).
Is the problem fixed?
The ControllerSIMM was bad
The ControllerPWB is probablybad. Run Test“Printing a TestMatrix PageWithout theController” onpage 252 to verifythat the problemis the Controllerand not the MCU.
6.
Is the symptom a continuous I/O INITIALIZING message? Go to “Ethernet /Token-Ring NICPrintingProblems” onpage 150
Go to step 7
7. Is the symptom a continuous WARMING UP or a continuous IBMINFOPRINT 20 message?
Go to step 8 Go to step 10
Chapter 2. Diagnosing Problems 138
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
8.
Solid rectangles usually indicate a controller problem, and WARMING UP... orIBM INFOPRINT 20 being displayed usually indicates an MCU problem. Testthe MCU by performing “Printing a Test Matrix Page Without the Controller” onpage 252.
Do the test pages print OK?
The MCU isfunctioningcorrectly. Replacethe ControllerSIMM (See“Controller PWBSIMM” onpage 539). If theproblem stillexists, replace theController PWB(See “ControllerPWB” onpage 537).
Go to step 9
9.
Rerun Printing a Test Matrix Page Without the Controller, ensuring that thefollowing are true:a. The paper path is clear.b. The EP cartridge is installed.c. Paper is loaded in Tray 1.d. The covers are closed.
Do the test pages print OK?
The MCU isfunctioningcorrectly. Replacethe ControllerSIMM (See“Controller PWBSIMM” onpage 539). If theproblem stillexists, replace theController PWB(See “ControllerPWB” onpage 537).
Bad MCU or 5Vpower problem.Go to “LVPS” onpage 163.
Chapter 2. Diagnosing Problems 139
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
10.Ensure that there are no paper jams, and that all covers are closed. Switch offthe printer power, then switch it back on.
Do both the fan and motor activate?
Go to step 11 Go to step 15
11.CONSOLE/OPERATOR PANEL
Wait one minute, watching the 4 lighted LEDs and display.
Do the LEDs and display function correctly?
Go to step 14 Go to step 12
12.Verify the connection at the console assembly and the controller. If theconnections seem OK, replace the console assembly (See page 418).
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 13
13.
There is a problem with one of the following components:v Console Harness (Asm-Index: 13-6, page 578)
v Controller Harness (Asm-Index: 13-8, page 578)
v LVPS Assembly (Asm-Index: 12-4, page 575)
14.When Online is pressed, the Online LED should turn off. The other keyscontrol menus.
Do the keys function correctly?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 12
15. Does the fan turn on? Go to “LVPS” onpage 163
Go to “Fuse orPower Problem”on page 127
Chapter 2. Diagnosing Problems 140
Table 28. Operator Panel, Controller, and Power Problems (continued)
Step Actions and Questions Yes No
16.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 141
Toner Low and No Error Code 02 Displayed
02 is not displayed when the EP Cartridge is empty.Table 29. 02 Not Displayed
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Toner Sensor Assembly (Asm-Index: 5-13, page 557)
v EP Cartridge (Asm-Index: 11-40, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v MSI Bracket Assembly (Asm-Index: 5-7, page 557)
v Toner Sensor Harness (Asm-Index: 5-17, page 557)
v Toner Relay Harness (Asm-Index: 12-18, page 575)
1.
EP CARTRIDGE (Asm-Index: 11-40, page 572)
a. Run a Test Print.b. Inspect the print quality.
Does the print appear light due to an empty EP Cartridge?
Go to step 2 Problem does notexist.
2.
TONER SENSOR (Asm-Index: 5-14, page 557)
a. Use “D21 SENSOR TEST” on page 261 to check the function of the TonerSensor.Note: Activate the sensor with a non-magnetized piece of steel.
Does the Toner Sensor function correctly?
Go to step 3 Go to “TonerSensor” onpage 176
Chapter 2. Diagnosing Problems 142
Table 29. 02 Not Displayed (continued)
Step Actions and Questions Yes No
3.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 143
Other DiagnosticsThese are secondary diagnostics branched to by other diagnostics.
24V Power Supply to MCUTable 30. 24V Power Supply to MCU
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v EP Cartridge (Asm-Index: 11-40, page 572)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Heater Assembly (Asm-Index: 9-5, page 567)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v High Harness Assembly (Asm-Index: 6-5, page 559)
1.
HARNESSa. Remove the Controller Assembly (See page 535).
b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575) andP/J123 from the LVPS Assembly (Asm-Index: 12-4, page 575).
c. Close the Pop Up Unit.d. Check for the continuity between J21-1 <=> J123.
Is there continuity between J21 <=> J123?
Go to step 2 Replace theInterlock Switch(See page 513)
Chapter 2. Diagnosing Problems 144
Table 30. 24V Power Supply to MCU (continued)
Step Actions and Questions Yes No
2.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
LVPS ASSEMBLYa. Disconnect P/J126.b. Switch ON the Main Power.c. Check the voltage between J123 <=> J126-2.
Is there 24VDC between J123 <=> J126-2?
Go to step 3 Replace the LVPSAssembly (Seepage 521)
3.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 145
Electrical NoiseTable 31. Electrical Noise
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v EP Cartridge (Asm-Index: 11-40, page 572)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Heater Assembly (Asm-Index: 9-5, page 567)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v High Harness Assembly (Asm-Index: 6-5, page 559)
1.
EXTERNAL NOISEa. Check if there is other electrical equipment, such as electrical generators,
radio transmitters, or devices using electrical motors, within ten feet of theprinter.
b. Shut off the other electrical equipment, or relocate the printer at leasttwenty feet away from other devices.
Is the Electrical Noise problem still present?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.AC GROUND
Check the AC wall outlet.
Is the AC wall outlet correctly wired and grounded?
Go to step 3 Have thecustomer repairthe AC wall outlet
Chapter 2. Diagnosing Problems 146
Table 31. Electrical Noise (continued)
Step Actions and Questions Yes No
3.EP CARTRIDGE
Replace the EP Cartridge.
Is the Electrical Noise problem still present?
Go to step 4 Verify the fix. Alsoverify that theproblem jobprints.
4.
LVPS ASSEMBLY (Asm-Index: 12-4, page 575)
Inspect the grounding screw for the cable connected to the Main PowerSwitch.
Is the cable grounded properly?
Go to step 5 Attach thegrounding screwproperly
5.
CRU GUIDE ASSEMBLY L (Asm-Index: 11-30, page 572)
a. Install the EP Cartridge.b. Inspect the spring contact on the CRU Guide Assembly L with the plate
terminals on the EP Cartridge.
Is the spring clean and does it contact the plate properly?
Go to step 6 Replace the CRUGuide Assembly L(See page 506)
6.
CRU GUIDE ASSEMBLY R (Asm-Index: 11-31, page 572)
a. Remove the EP Cartridge.b. Inspect the ground spring on the rear end of the CRU Guide Assembly R
(Asm-Index: 11-31, page 572).
Is the ground spring intact free of contamination and deformation?
Go to step 7 Clean the groundspring or replacethe CRU GuideAssembly R (Seepage 510)
7.
TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559)
a. Remove the Transport Chute Assembly (See page 468).
b. Check for the continuity on all the wires in the Transport Chute Assembly.
Is there continuity on all the wires?
Go to step 8 Replace theTransport ChuteAssembly (Seepage 468)
Chapter 2. Diagnosing Problems 147
Table 31. Electrical Noise (continued)
Step Actions and Questions Yes No
8.
DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page559)
Inspect the DTS and the TR wires.
Are the wires connected properly?
Go to step 9 Connect the wiresproperly.
9.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
HEATER ASSEMBLY (Asm-Index: 9-5, page 567)
Inspect the cables of P142-1 and the right end of the HeaterRod.
Are the cables attached properly?
Go to step 10 Attach the cablesproperly
10.
HVPSa. Remove the Controller Assembly (See page 535).
b. Disconnect P/J15 from the MCU PWB (Asm-Index: 12-8, page 575).
c. Run a Test Print (continuously approximately ten sheets).
Do the Test Prints run normally?
Replace theHVPS (See page532)
Go to step 11
11.Replace the MCU PWB (See page 526 or 529)
Is the problem still present?
Go to step 12 Verify the fix. Alsoverify that theproblem jobprints.
12.Inspect all of the grounds in the printer.
Are the grounds proper?
Replace theSuspectComponents
Repair the badgrounds
Chapter 2. Diagnosing Problems 148
Table 31. Electrical Noise (continued)
Step Actions and Questions Yes No
13.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 149
Ethernet / Token-Ring NIC Printing Problems
Note: If the network interface card is installed, but not connected to the LAN, a page with network interfacecard details will be printed. You can also print this page from the Test Menu.
Table 32. Ethernet/Token-Ring NIC Printing Problems
Step Actions and Questions Yes No
1.Is the problem only with IPDS jobs?Note: To answer this questions, you may need to ask the SystemAdministrator to send a PCL or PS job.
Go to step 2 Go to step 3
2.
Print a Config Page (see “Configuration Page” on page 250).
Is IPDS indicated on the Config Page?
There is probablya configurationproblem. Referthe SystemAdminstrator to“Ethernet andToken Ring QuickConfigurationGuide”,G544-5499.
Reseat the IPDSSIMM. If thatdoes not fix theproblem, install anew IPDS SIMM.
3.
Switch on the printer power. Wait for the READY message. Wait for the full 5minutes (you may get an error code after the printer times out).
Does READY appear within 5 minutes?
Go to step 4 Return to“Diagnostic QuickPath” on page 28with the new errorcode or symptom.
Chapter 2. Diagnosing Problems 150
Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)
Step Actions and Questions Yes No
4.
If a NIC configuration page prints approximately 2 minutes after power isswitched on, the NIC is working correctly. But there is probably a problem inthe LAN connection for that NIC.
Did a NIC Configuration page print for each installed NIC?Note: If your printer has both Ethernet and a token ring NIC, determine whichNIC configuration page printed. A NIC configuration page will be printed for aNIC that has a LAN connection problem.
The printer andNIC are OK.
If the problem stillexists, problems,there is probablya LAN cable orLAN configurationproblem.
Refer the SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.
Go to step 5
5.
Try to print a configuration page for the printer (not a NIC configuration page)using TEST MENU/CONFIG PAGE.
Does the TEST MENU/CONFIG PAGE print?
Verify that eachNetwork InterfaceCard has aunique IPaddress. Go tostep 6
Return to“Chapter 1.Getting Started”on page 25 with
the new errorcode or symptom.
6. Look at the printer configuration page. Is each installed NIC indicated onthe printer configuration page?
Go to step 7 Go to step 9
7. Can you print a NIC Config Page for each installed NIC from the printer(TEST MENU/PRINT EN CONFIG or TEST MENU/PRINT TR CONFIG)?
Go to step 8 Go to step 9
Chapter 2. Diagnosing Problems 151
Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)
Step Actions and Questions Yes No
8.
The printer and NIC seem OK.
Check the LEDs on the back of the NIC; they should be as follows:v Token ring
RING NSRT = ONSPD ERROR = OFF
v EthernetUTP (10base-T) LINK = on and NET ACT = on (flashes intermittently)BNC (10base2) LINK = off and NET ACT = on (flashes intermittently)
Do the LEDs match the ″properly connected ″ definition?
The printer, NIC,and LANconnection seemOK.
Suspect a job orconfigurationproblem. Referthe SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.
There is a LANcablingconfigurationproblem. Referthe SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.
9.
The NIC that is not shown on the printer configuration page, or the Controllerhas a problem.v Power off.v Reseat the NIC.v Power on and wait for 5 minutes.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 10
Chapter 2. Diagnosing Problems 152
Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)
Step Actions and Questions Yes No
10.
Reset the NIC jumpers as follows:a. Switch off printer power.b. Remove the NIC.c. Move jumper JX1 to the RST (reset) position.d. Reinstall the NIC.e. Switch on printer power and wait until READY displays.f. Switch off printer power.g. Move jumper JX1 to the original position.h. Reinstall the NIC.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
If there is onlyone NIC in theprinter, go to step11. If you haveanother NIC, youcan try swappingNIC positions onthe controller toisolate NIC vsController.
11.
Install a new NIC.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Replace theController SIMM(see “ControllerPWB” onpage 537) or theController PWB(See “ControllerPWB” onpage 537)
Chapter 2. Diagnosing Problems 153
Table 32. Ethernet/Token-Ring NIC Printing Problems (continued)
Step Actions and Questions Yes No
12.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 154
Feed SolenoidTable 33. Feed Solenoid
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Feed Solenoid (Asm-Index: 4-8, page 555)
v Feeder PWB (Asm-Index: 3-1, page 553)
v MCU PWB (Asm-Index: 12-8, page 575)
v Cassette Guide Assembly L (Asm-Index: 3-6, page 553), including theFeeder Harness (Asm-Index: 3-12, page 553)
v Tray Harness (Asm-Index: 12-17, page 575)
1.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
FEED SOLENOID POWER SUPPLYa. Remove the Controller Assembly (See page 535)
b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).
c. Check the voltage between P/J20-A11 <=> P/J20-B1.
Is there 24VDC between P20-A11 <=> P20-B1?
Go to step 3 Go to step 2
Chapter 2. Diagnosing Problems 155
Table 33. Feed Solenoid (continued)
Step Actions and Questions Yes No
2.
CONTINUITY ON MCU PWB (Asm-Index: 12-8, page 575)
a. Disconnect P/J21 from the MCU PWB.b. Check for the continuity between P13-9 <=> P21-1.
Is there continuity between P13-9 <=> P21-1?
Go to “24V PowerSupply to MCU”on page 144
Replace the MCUPWB (See page526 or 529)
3.
Does the problem appear when using Tray 2 or 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661, or“Appendix H.2000-Sheet InputDrawer Option” onpage 703.
Go to step 4
4.
FEEDER PWB (Asm-Index: 3-1, page 553)
a. Disconnect P/J201, P/J202 and P/J203 from the Feeder PWB (Asm-Index:3-1, page 553).
b. Check for the continuity between P201 <=> P202 <=> P203 below:v P201-A1 <=> P202-A1 <=> P203-8v P201-A8 <=> P203-9
Is the continuity on wires above between P201 <=> P202 <=> P203?
Go to step 5 Replace theFeeder PWB (Seepage 420)
5.
PICK UP SOLENOID (Asm-Index: 6-17, page 559)
a. Leave P/J203 disconnected.b. Check the resistance between J203-8 <=> J203-9.
Is there approximately 120 ohms resistance between J203-8 <=> P203-9?
Go to step 7 Go to step 6
Chapter 2. Diagnosing Problems 156
Table 33. Feed Solenoid (continued)
Step Actions and Questions Yes No
6.
FEEDER HARNESS (Asm-Index: 3-12, page 553)
a. Leave P/J203 disconnected and disconnect P/J204 from the FeedSolenoid (Asm-Index: 4-8, page 555).
b. Check for the continuity on wires between J203-8 <=> J204-2 and J203-9<=> J204-1.
Is there continuity on both wires?
Replace the FeedSolenoid (Seepage 446)
Replace theFeeder Harness
7.
TRAY HARNESS (Asm-Index: 12-17, page 575)
a. Leave P/J20 disconnected.b. Check for the continuity on wires between J20 <=> P201 of the Tray
Harness below:v J20-A10 <=> J201-A1v J20-A4 <=> J201-A8
Is there continuity on wires above between J20 <=> P201?
Go to step 8 Replace the TrayHarness
Chapter 2. Diagnosing Problems 157
Table 33. Feed Solenoid (continued)
Step Actions and Questions Yes No
8.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
FEEDER PWB (Asm-Index: 3-1, page 553)
a. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).
b. Check the voltage between P203-8 <=> P/J20-B1 andP203-9 <=> P/J20-B1.
Is there 24VDC between P203-8 <=> P/J20-B1 and P203-9<=> P/J20-B1?
Replace the MCUPWB (See page526 or 529)
Replace theFeeder PWB (Seepage 420)
9.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 158
HVPSTable 34. HVPS
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v HVPS (Asm-Index: 12-11, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v HVPS Harness (Asm-Index: 12-15, page 575)
v EP Cartridge (Asm-Index: 11-40, page 572)
v High Harness Assembly (Asm-Index: 6-5, page 559)
1.
CRU GUIDE ASSEMBLY L POWER SUPPLYa. Ensure that an EP Cartridge is installed.b. Inspect Spring contact on the CRU Guide Assembly L and the plate
terminals on the EP Cartridge.
Are the Spring contacting the plate terminals properly?
Go to step 2 Replace the CRUGuide Assembly L(See page 506)
2.
CRU GUIDE ASSEMBLY L POWER SUPPLYa. Remove the HVPS (See page 532) while performing next step.
b. Inspect the Spring contact on the CRU Guide Assembly L and the HVPSduring the removal of the HVPS.
Does the Spring contact the HVPS properly?
Go to step 3 Replace the CRUGuide Assembly L(See page 506).
Chapter 2. Diagnosing Problems 159
Table 34. HVPS (continued)
Step Actions and Questions Yes No
3.
CRU GUIDE ASSEMBLY R METAL GROUNDING PLATEa. Remove the EP Cartridge (Asm-Index: 11-40, page 572).
b. Inspect the Metal Grounding Plate on the rear end of the CRU GuideAssembly R (Asm-Index: 11-31, page 572).
Is the Metal Grounding Plate intact, free of contamination, deformation ordamage?
Go to step 4 Replace the CRUGuide AssemblyR (See page 510)
4.
HVPS HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)
a. Remove the Controller Assembly (See page 535).
b. Disconnect P/J15 and P/J151 from the MCU PWB and HVPS.c. Check for the continuity between J15 <=> J155 as below:v J15-1 <=> J151-13v J15-8 <=> J151-6v J15-2 <=> J151-12v J15-9 <=> J151-5v J15-3 <=> J151-11v J15-10 <=> J151-4v J15-4 <=> J151-10v J15-11 <=> J151-3v J15-5 <=> J151-9v J15-12 <=> J151-2v J15-6 <=> J151-8v J15-13 <=> J151-1v J15-7 <=> J151-7
Is there continuity between J15 <=> J155?
Go to step 5 Replace theHVPS Harness
Chapter 2. Diagnosing Problems 160
Table 34. HVPS (continued)
Step Actions and Questions Yes No
5.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
24VDCa. Switch ON the Main Power.b. Check the voltage between P15-1 and the Printer Frame.
Is the voltage between P15-1 and the Printer Frame 24VDC?
Go to step 7 Go to step 6
6.
MCU PWB (Asm-Index: 12-8, page 575)
a. Switch OFF the Main Power.b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).
c. Check for the continuity between P21-1 <=> P15-1.
Is there continuity between P21-1 <=> P15-1?
Go to “24V PowerSupply to MCU”on page 144
Replace the MCUPWB (See page526 or 529)
7.Replace the MCU PWB (See page 526 or 529)
Does the problem still appear?
Go to step 8 Verify the fix. Alsoverify that theproblem jobprints.
8.Replace the HVPS (See page 532)
Does the problem still appear?
Go to step 9 Verify the fix. Alsoverify that theproblem jobprints.
Chapter 2. Diagnosing Problems 161
Table 34. HVPS (continued)
Step Actions and Questions Yes No
9.
DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page559)
a. Remove the Transport Chute Assembly (See page 468)
b. Disconnect the DTS and TR Plugs from the HVPS (Asm-Index: 12-11,page 575) and from the Transport Chute Assembly.
c. Check for the continuity between both ends of the DTS and TR wires.
Is there continuity through the DTS and TR wires?
Call technicalsupport (see“Appendix D.TechnicalSupport” onpage 602).
Replace the wiresthat do not havecontinuity (DTS orTR) that arecontained in theHigh HarnessAssembly (Seepage 468 for theremovalprocedure)
10.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 162
LVPSTable 35. LVPS
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v LVPS Assembly (Asm-Index: 12-4, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Harness (Asm-Index: 12-14, page 575)
1.
LVPS ASSEMBLY (Asm-Index: 12-4, page 575)
a. Disconnect P/J121 and P/J126.b. Switch ON the Main Power.c. Check the voltage between P121-5 <=> P121-4 and P126-1 <=> P126-2.
Is there 5VDC between P121-5 <=> P121-4, and P126-1 <=> P126-2?
Go to step 2 Replace the LVPSAssembly (Seepage 521)
2.
LVPS HARNESS (Asm-Index: 12-14, page 575)
a. Switch OFF the Main Power.b. Disconnect P/J11.c. Check for the continuity between J11 <=> J121 as below:v J11-1 <=> J121-6v J11-2 <=> J121-5 (+5V)v J11-3 <=> J121-4v J11-4 <=> J121-3v J11-5 <=> J121-2v J11-6 <=> J121-1 (+24V)
Is there continuity between J11 <=> J121?
Go to step 3 Replace the LVPSHarness
Chapter 2. Diagnosing Problems 163
Table 35. LVPS (continued)
Step Actions and Questions Yes No
3.AC WALL OUTLET
Check the AC wall outlet.
Is the AC wall outlet correctly wired and grounded?
Replace the MCUPWB (See page526 or 529)
Notify customer ortheir electrician.
4.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 164
Paper Size Switch - 500-Sheet Paper Trays
The ″Autosensed Paper″ size indicated on the CONFIG PAGE does not match the tray size guide positions.
The following table shows the combination of size switches activated (’1’) for each size paper.Table 36. Paper Size Switches
Paper SizePaper Size Switch
SW4 Bottom SW3 SW2 SW1 Top
Cassette removed 0 0 0 0
Universal (Non-regular size) 1 0 0 0
11x17 (Ledger) SEF 0 0 0 1
A3 SEF 0 0 1 0
B4 SEF 0 0 1 1
Legal 14″ SEF 0 1 0 0
Legal 13″ SEF 0 1 0 1
A4 SEF ¹ 0 1 1 0
Letter SEF ² 0 1 1 0
B5 LEF 1 1 0 1
Letter LEF 1 0 1 0
A4 LEF 1 0 1 1
Executive LEF 1 1 0 1
A5 LEF ¹ 1 1 1 1
Statement LEF ² 1 1 1 1
Postcard SEF ¹ 0 1 1 1
Chapter 2. Diagnosing Problems 165
Table 36. Paper Size Switches (continued)
Paper SizePaper Size Switch
SW4 Bottom SW3 SW2 SW1 Top
C5 SEF ² 0 1 1 1
COM-10 1 1 1 0
DL SEF 1 1 0 0
Monarch SEF 1 0 0 1
Notes:
1. Only when the printer is switched on while pressing ONLINE (Cold Reset to LTR defaults)2. Only when the printer is switched on while pressing CANCEL (Cold Reset to A4 defaults)
Chapter 2. Diagnosing Problems 166
Table 37. Paper Size Switch
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Paper Cassette (Asm: 2, page 550)
v Feeder PWB (Asm-Index: 3-1, page 553)
v Cassette Guide Assembly (Asm-Index: 3-6, page 553)
v Tray Harness (Asm-Index: 12-17, page 575)
v Tray Lower1 Harness (Asm-Index: 3-2, page 553)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1.
PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS
Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page553). See Table 36 on page 165.
Do the Size Cam states match the loaded paper size?
Go to step 3 Go to step 2
Chapter 2. Diagnosing Problems 167
Table 37. Paper Size Switch (continued)
Step Actions and Questions Yes No
2.
PAPER SIZE CAM MECHANICS
Inspect the suspect components and their settings relating to the Size Camas:v End Guide Plate (Asm-Index: 2-14, page 550)
v Paper End Guide (Asm-Index: 2-15, page 550)
v End Guide Spring (Asm-Index: 2-16, page 550)
v End Guide (Asm-Index: 2-17, page 550)
v Pivot Plate (Asm-Index: 2-18, page 550)
v Sector Gear (Asm-Index: 2-19, page 550)
v Size Cam (Asm-Index: 2-20, page 550)
Are any of these components damaged or installed incorrectly?
Repair or replacethe PaperCassette asnecessary
If the tray is anoptional Tray 2 or3, install a newTray Feeder(Asm: 20, page697), or replacethe entire option.
For Tray 1,replace theCassette GuideAssembly Left(See page 426).
3.
PAPER SIZE SWITCHES
The cams seem to actuate correctly, but the wrong size is reported.a. Remove the Paper from the Paper Cassette.b. Use “D21 SENSOR TEST” on page 261 to check the Paper Size Switches.
c. Reach inside the paper feeder and press and release one Size Actuator(Asm-Index: 3-8, page 553). Press ENTER and repeat for each switch.
Do the Size Switches function correctly?
Possible MCUproblem
If the tray is anoptional Tray 2 or3, replace theoption.
For Tray 1, go tostep 4.
Chapter 2. Diagnosing Problems 168
Table 37. Paper Size Switch (continued)
Step Actions and Questions Yes No
4.
PAPER SIZE SWITCH OF THE FEEDER PWBa. Remove the Feeder PWB (See page 420).
b. Check for the continuity between two terminals of each Paper Size Switchwhile you press and release it.
Is there continuity through the switch when you press the Size Actuatorand no continuity when you release it?
Go to step 5 Replace theFeeder PWB (Seepage 420)
5. There is a problem with one of the Suspect Components.
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 169
Pick Up Solenoid (Auxiliary Tray)
Note: You can test the Auxiliary Tray Pick Up Solenoid using “D50 SOL TRAY A (Auxiliary Tray FeedSolenoid)” on page 277.
Table 38. Pick Up Solenoid
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Pick Up Solenoid (Asm-Index: 6-17, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
1.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
PICK UP SOLENOID POWER SUPPLYa. Remove the Controller Assembly (See page 535).
b. Check the voltage between P/J13-9 <=> ground.
Is there 24VDC between P/J13-9 <=> ground?
Go to step 3 Go to step 2
2.
CONTINUITY ON MCU PWBa. Power off the printer.b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).
c. Check for the continuity between P13-9 <=> P21-1.
Is there continuity between P13-9 <=> P21-1?
Go to “24V PowerSupply to MCU”on page 144
Replace the MCUPWB (See page526 or 529)
Chapter 2. Diagnosing Problems 170
Table 38. Pick Up Solenoid (continued)
Step Actions and Questions Yes No
3.
PICK UP SOLENOID (Asm-Index: 6-17, page 559)
a. Power off the printer.b. Disconnect P/J13 from the MCU PWB.c. Check the resistance between J13-9 <=> J13-10.
Is there approximately 90 ohms between J13-9 <=> J13-10?
Replace the MCUPWB (See page526 or 529)
Go to step 4
4.
HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)
a. Leave P/J13 disconnected and disconnect P/J135 from the harnessleading to the MSI Feed Solenoid.
b. Check for the continuity on the two wires.
Is there continuity on both wires?
Replace the PickUp Solenoid (Seepage 477)
Replace the HighHarnessAssembly
5.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 171
Registration SensorTable 39. Registration Sensor
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Registration Sensor (Asm-Index: 7-6, page 562)
v Registration Actuator (Asm-Index: 7-7, page 562)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
v High Harness Assembly (Asm-Index: 6-5, page 559)
v LVPS Assembly (Asm-Index: 12-4, page 575)
1.
RESISTRATION SENSOR and ACTUATOR (Asm-Index: 7-6 and 7-7, page562)
a. Remove the Rear Tie Plate (part of “Registration Sensor/Actuator” onpage 484).
b. Push up and then release the Registration Actuator and inspect therelative position with the detecting point of the Registration Sensor.
Is the arm of the Registration Actuator away from the detecting point ofthe Registration Sensor when you push up the Actuator? Does the armshield the detecting point of the Sensor when you release the Actuator?
Go to step 2 Replace theRegistrationSensor and/orActuator (Seepage 484)
Chapter 2. Diagnosing Problems 172
Table 39. Registration Sensor (continued)
Step Actions and Questions Yes No
2.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
REGISTRATION SENSOR POWER SUPPLYa. Remove the Controller Assembly (See page 535).
b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).
c. Disconnect P/J13, and then check the voltage between P13-3<=> P13-4.
Is there 5VDC between P13-3 <=> P13-4?
Go to step 4 Go to step 3
3.
CONTINUITY ON MCU PWBa. Disconnect P/J11 from the MCU PWB (Asm-Index: 12-8, page 575).
b. Check for the continuity between P11-5 <=> P13-3.
Is there continuity between P11-5 <=> P13-3?
Go to “LVPS” onpage 163
Replace the MCUPWB (See page526 or 529)
Chapter 2. Diagnosing Problems 173
Table 39. Registration Sensor (continued)
Step Actions and Questions Yes No
4.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
POWER SUPPLY TO THE REGISTRATION PAPER DETECTORa. Leave P/J12, P/J15 and P/J17 on the MCU PWB
disconnected.b. Check the voltage between P/J13-5 <=> P/J13-4.
Is there 5VDC between P/J13-5 <=> P/J13-4?
Go to step 5 Replace the MCUPWB (See page526 or 529)
5.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
REGISTRATION SENSOR SIGNALa. Leave P/J12, P/J15 and P/J17 on the MCU PWB
disconnected.b. Press and release the Registration Actuator (Asm-Index: 7-7,
page 562).
c. Check the voltage between P/J13-5 <=> P/J13-4.
Is there 0VDC between P/J13-5 <=> P/J13-4 when you pressthe Actuator, and 5VDC when you release it?
Replace the MCUPWB (See page526 or 529)
Go to step 6
Chapter 2. Diagnosing Problems 174
Table 39. Registration Sensor (continued)
Step Actions and Questions Yes No
6.
HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)
a. Disconnect P/J13 and P/J132.b. Check for the continuity on each wire between J13-3 <=> J132-3, J13-4
<=> J132-2, and J13-5 <=> J132-1.
Is there continuity between J13 <=> J132?
Replace theRegistrationSensor (See page484)
Replace the HighHarnessAssembly
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 175
Toner SensorTable 40. Toner Sensor
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Toner Sensor Assembly (Asm-Index: 5-13, page 557)
v MCU PWB (Asm-Index: 12-8, page 575)
v Toner Sensor Harness (Asm-Index: 5-17, page 557)
v Toner Relay Harness (Asm-Index: 12-18, page 575)
v MSI Bracket Assembly (Asm-Index: 5-7, page 557)
1.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
TONER SENSOR POWER SUPPLYa. Remove the Controller Assembly (See page 535).
b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).
c. Check the voltage between P/J22-1 <=> P/J22-3.
Is there 24VDC between P/J22-1 <=> P/J22-3?
Go to step 3 Go to step 2
2.
CONTINUITY ON MCU PWBa. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).
b. Check for the continuity between P22-1<=> P21-1.
Is there continuity between P22-1 <=> P21-1?
Go to “24V PowerSupply to MCU”on page 144
Replace the MCUPWB (See page526 or 529)
Chapter 2. Diagnosing Problems 176
Table 40. Toner Sensor (continued)
Step Actions and Questions Yes No
3.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
TONER DETECTOR SIGNALa. Leave P/J12, P/J15 and P/J17 on the MCU PWB
disconnected.b. Check the voltage between P22-4 <=> P22-3.
Is there 5VDC between P22-4 <=> P22-3?
Go to step 4 Replace the MCUPWB (See page526 or 529)
4.
DANGER
<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.
TONER DETECTOR SIGNALa. Leave P/J12, P/J15 and P/J17 disconnected.b. Press down and hold the Interlock Switch (Asm-Index: 12-1,
page 575).
c. Check the voltage between P22-4 <=> P22-3 while youremove and reinstall the EP Cartridge.
Is there 0VDC between P22-4 <=> P22-3 when you install theEP Cartridge, and 5VDC when you remove it?
Replace the MCUPWB (See page526 or 529)
Go to step 5
Chapter 2. Diagnosing Problems 177
Table 40. Toner Sensor (continued)
Step Actions and Questions Yes No
5.
TONER RELAY HARNESS (Asm-Index: 12-18, page 575)
a. Disconnect P/J22 from the MCU PWB and P/J222 from the harnessleading to the Toner Sensor (Asm-Index: 5-14, page 557).
b. Check for the continuity of each wire between J22 <=> J222.
Is there continuity between J22 <=> J222?
Go to step 6 Replace the TonerRelay Harness
6.
TONER SENSOR HARNESS (Asm-Index: 5-17, page 557)
a. Disconnect P/J221 from the Toner Sensor and leave P/J222 disconnected.b. Check for the continuity of each wire between J221 <=> P222.
Is there continuity between J221 <=> P222?
Replace the TonerSensor Assembly(See page 462)
Replace the TonerSensor Harness
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 178
Twinax / Coax NIC Printing ProblemsNotes:1. For Twinax NICs, ensure that the printer station address is set correctly in the TWINAX SETUP MENU
(IPDS ADDR or SCS ADDR).2. If the printer has had a ″cold reset″, have the user ensure that all menus have been tailored to their
original settings. If necessary, see an old Config Page printout.Table 41. Twinax/Coax NIC Printing Problems
Step Actions and Questions Yes No
1. Is the problem only with IPDS jobs? Go to step 2 Go to step 3
2.
Print a Config Page (see page 250).
Is IPDS indicated on the Config Page?
Verify that there isenough memoryfor IPDS jobs.Refer to the IBMInfoPrint 20:User’s Guide formemoryrequirements. Goto step 3.
Reseat the IPDSSIMM. If thatdoes not fix theproblem, install anew IPDS SIMM.
3.
Switch on the printer power. Wait for the READY message.
Does READY appear within 5 minutes?
Go to step 4 Return to“Chapter 1.Getting Started”on page 25 with
the new errorcode or symptom.
Chapter 2. Diagnosing Problems 179
Table 41. Twinax/Coax NIC Printing Problems (continued)
Step Actions and Questions Yes No
4.
Can you print a printer Config Page? Go to step 5 Return to“Chapter 1.Getting Started”on page 25 with
the new errorcode or symptom.
5. Is the Twinax or Coax NIC indicated on the printer Config Page? Go to step 6 Go to step 10
6. Can you print a NIC Config Page from the Test button on the back of theNIC?
Go to step 7 Go to step 10
7.
When a job is sent, does the printer operator panel indicate its arrivalwith a message such as ″TX IPDS″ or ″CX IPDS″?
The cabling andNIC are OK.Suspect aproblem withmenu settings,the IPDS SIMM,or the controllerSIMM/board.
Go to step 8
Chapter 2. Diagnosing Problems 180
Table 41. Twinax/Coax NIC Printing Problems (continued)
Step Actions and Questions Yes No
8.
Check the green LED (labelled CU) on the back of the NIC.
Is the green LED On or Blinking?
The NIC isreceiving pollsfrom the system.Suspect a job orconfigurationproblem. Referthe SystemAdministrator tothe IBM NetworkPrinters: Twinaxand CoaxConfigurationGuide or TechSupport.Note: If theShare light is alsoon when theprinter is READY,install a new NIC.
Go to step 9
Chapter 2. Diagnosing Problems 181
Table 41. Twinax/Coax NIC Printing Problems (continued)
Step Actions and Questions Yes No
9.
The NIC can communicate with the controller, but the system cannotcommunicate with the NIC.
Check the cable connection at the back of the Twinax of Coax NIC.
Is the connection OK?
There is probablya network cablingproblem or aconfigurationproblem. Referthe SystemAdministrator tothe IBM NetworkPrinters: Twinaxand CoaxConfigurationGuide or TechSupport (see“Appendix D.TechnicalSupport” onpage 602).
Replace the NIC
10.
There is a problem with the NIC or Controllerv Power off.v Reseat the NICv Power on and wait.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
If there is onlyone NIC in theprinter, go to step11. If you haveanother NIC, youcan try swappingNIC positions onthe controller toisolate NIC vsController.
Chapter 2. Diagnosing Problems 182
Table 41. Twinax/Coax NIC Printing Problems (continued)
Step Actions and Questions Yes No
11.
Install a new NIC (See “Network Interface Card” on page 541)
Is the problem fixed?
Verify the fix. Alsoverify that theproblem jobprints.
Replace theController SIMM(See “ControllerPWB SIMM” onpage 539)or theController PWB(See “ControllerPWB” onpage 537)
12.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 183
Print QualityBackground
PROBLEM: There is toner contamination on all or part of the page. The contamination appears as a light graydusting.
hc2m211F
Chapter 2. Diagnosing Problems 184
Table 42. Background
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v Fuser Assembly (Asm-Index: 8-1, page 564)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
PRINT DENSITYa. Find the white volume knob near the left end of the EP cartridge. Ensure
that it is at the nominal position (centered between +1 and -1).b. Adjust CONFIG MENU/DENSITY to a lower setting.c. Run a Test Print.d. If necessary, try adjusting the knob clockwise to a higher position.
Is the background gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
2.
EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.
Is the background gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 3
Chapter 2. Diagnosing Problems 185
Table 42. Background (continued)
Step Actions and Questions Yes No
3.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through the
print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
drum just before the transfer area (BTR).
Are the undeveloped areas of the drum clean and without background?
Go to step 4 Go to “HVPS” onpage 159
4.
TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559) GROUND
a. Remove the EP Cartridge (Asm-Index: 11-40, page 572).
b. Check for the continuity, from the front opening, between metal parts of theTransport Chute Assembly and the Printer Frame.
Is the Transport Chute Assembly grounded?
Go to step 5 Remove andreinstall theTransport ChuteAssembly (Seepage 468), so thatit is groundedproperly.
5.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564) GROUND
a. Open the Fuser Cover Assembly.b. Check for the continuity between the screw located at the back side of the
Fuser Assembly and the Printer Frame.
Is the Fuser Assembly grounded?
Go to the laststep of thisdiagnostic.
Remove andreinstall the FuserAssembly (Seepage 487), so thatit is groundedproperly.
Chapter 2. Diagnosing Problems 186
Table 42. Background (continued)
Step Actions and Questions Yes No
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 187
Black Prints
PROBLEM: The entire print is black.
Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of thisproblem, see “Operator Panel, Controller, and Power Problems” on page 135.
hc2m203F
Chapter 2. Diagnosing Problems 188
Table 43. Black Prints
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v HVPS Harness (Asm-Index: 12-15, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.
Is the print normal?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
2.
HVPS (Asm-Index: 12-11, page 575)
a. Shield the entire window of the ROS Assembly (Asm-Index: 11-20, page572).
b. Run a Test Print.
Is the print black?
Go to “HVPS” onpage 159
Go to step 3
3.
ROS ASSEMBLY (Asm-Index: 11-20, page 572)
a. Shield half of the window of the ROS Assembly.b. Run a Test Print.
Is the print half white and half black?
Go to the laststep of thisdiagnostic.
Replace the MCUPWB (See page526 or 529)
Chapter 2. Diagnosing Problems 189
Table 43. Black Prints (continued)
Step Actions and Questions Yes No
4.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 190
Blank Prints
PROBLEM: The entire print is blank.
Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of thisproblem, see “Operator Panel, Controller, and Power Problems” on page 135.
hc2m202F
Chapter 2. Diagnosing Problems 191
Table 44. Blank Prints
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v HVPS Harness (Asm-Index: 12-15, page 575)
v Pop Up Frame (Asm-Index: 11-1, page 572)
v CRU Latch (Asm-Index: 11-13, page 572)
v CRU Latch Spring (Asm-Index: 11-14, page 572)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
EP CARTRIDGEa. Install new EP Cartridge.b. Reprint the problem image.
Is there a normal image on the paper?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
Chapter 2. Diagnosing Problems 192
Table 44. Blank Prints (continued)
Step Actions and Questions Yes No
2.
DRUM GROUNDa. Remove the EP Cartridge.b. Inspect the metal grounding plate on the rear end of the CRU Guide
Assembly R (Asm-Index: 11-30, page 572).
Is the metal grounding plate intact, not contaminated and not deformed?
Go to step 3 Reform or cleanthe MetalGrounding Plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).
3.
GROUND OF THE METAL GROUNDING PLATE
Check for the continuity between the Metal Grounding Plate and the printerframe.
Is there continuity between the Grounding Plate and the printer frame?
Go to step 4 Replace the CRUGuide AssemblyR (See page 510)
4.BTR ASSEMBLY (Asm-Index: 6-1, page 559)
Is the BTR intact, not contaminated?
Go to step 5 Replace BTRAssembly (Seepage 466)
5.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF power halfway through the print
cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
drum just before the transfer area (BTR).
Is the image on the drum completely developed, with sharp, black, easilyread areas?
Go to step 6 Go to “HVPS” onpage 159
Chapter 2. Diagnosing Problems 193
Table 44. Blank Prints (continued)
Step Actions and Questions Yes No
6.
IMAGE TRANSFER PROCESS
Inspect the toner image on the drum immediately after the transfer area(BTR).
Was any of the toner image on the drum transferred to the paper?
Problem with theBTR Assembly orwiring
Go to “HVPS” onpage 159
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 194
Black Horizontal Stripes
PROBLEM: The print contains black horizontal stripes of varying widths.
Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with black horizontal stripes of varying widths may print.
To diagnose this problem, see “Operator Panel, Controller, and Power Problems” on page 135.
hc2m215F
Chapter 2. Diagnosing Problems 195
Damaged Print
PROBLEM: The printed page comes out of the printer either wrinkled, creased, or torn.
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Chapter 2. Diagnosing Problems 196
Table 45. Damaged Print
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564)
v MCU PWB (Asm-Index: 12-8, page 575)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v EP Cartridge (Asm-Index: 11-40, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Pick Up Roll (Asm-Index: 6-8, page 559)
v Retard Pad Assembly (Asm-Index: 6-18, page 559)
v Rear Roll Assembly (Asm-Index: 4-11, page 555)
v Turn Roll Assembly (Asm-Index: 4-10, page 555)
v Turn Chute Assembly (Asm-Index: 3-5, page 553)
v Turn In Chute (Asm-Index: 3-4, page 553)
v Feed Roll (Asm-Index: 4-1, page 555)
v Paper Cassette (Asm: 2, page 550)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.PAPER FEED
Observe paper feed.
Is the paper fed crooked?
Go to “SkewedImage” onpage 212
Go to step 2
Chapter 2. Diagnosing Problems 197
Table 45. Damaged Print (continued)
Step Actions and Questions Yes No
2.
PAPER CONDITIONSa. Replace paper with fresh, dry standard paper.b. Run a Test Print.
Is the paper still damaged?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
3.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567)and PRESSURE ROLL (Asm-Index: 9-15, page 567)
a. Open the Pop Up Unit.b. Open the Fuser Cover Assembly and the Fuser Rear
Assembly (Asm-Index: 8-10, page 564).
c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll and the Pressure Roll.
Are the Heat Roll and the Pressure Roll free of scratchesand contamination?
Go to step 4 Clean or replacethe FuserAssembly (Seepage 487)
4.
PAPER PATH
Inspect the paper path between the feed tray and the exit tray forcontamination or obstructions.
Is the paper path free of obstructions?
Go to step 5 Removeobstructions orcontaminationfrom the paperpath.
Chapter 2. Diagnosing Problems 198
Table 45. Damaged Print (continued)
Step Actions and Questions Yes No
5.
PAPER PATH ROLLS
Inspect all of the rolls along the paper path between the feed tray and the exittray for contamination, wear or damage.
Are the paper path rolls free of contamination, wear, or damage?
Go to step 6 Replace thedamaged or wornroll. (See“Chapter 6.RemovalProcedures,Adjustments” onpage 394)
6.
EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.
Is the print still damaged?
Go to step 7 Verify the fix. Alsoverify that theproblem jobprints.
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 199
Fusing, Not Fused or Partially Fused Image
PROBLEM: The printed image is not fully fused to the paper. The image easily rubs off.
hc2m214F
Table 46. Fusing, Not Fused or Partially Fused Image
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Fuser Assembly (Asm-Index: 8-1, page 564)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
PAPER CONDITIONSa. Replace the paper with fresh, dry standard paper.b. Reprint the problem image.
Is the problem still present?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
Chapter 2. Diagnosing Problems 200
Table 46. Fusing, Not Fused or Partially Fused Image (continued)
Step Actions and Questions Yes No
2.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567)and PRESSURE ROLL (Asm-Index: 9-15, page 567)
a. Open the Pop Up Unit.b. Remove the Fuser Assembly (See page 487).
c. Inspect the Heat Roll and Pressure Roll rotating the Exit Gear(Asm-Index: 9-29, page 567) manually.
Are the Heat Roll and the Pressure Roll free of scratchesand contamination?
Reinstall theFuser Assembly(See page 487).Go to step 3.
Clean or replacethe FuserAssembly (Seepage 487)
3.
FUSER ASSEMBLY (Asm-Index: 8-1, page 564)
a. Rotate the Exit Gear Manually.b. Inspect the contact between the Heat Roll and the Pressure Roll along the
rotation.
Are the Heat Roll and the Pressure Roll contacting each other uniformly?
Go to step 4 Replace theFuser Assembly(See page 487)
Chapter 2. Diagnosing Problems 201
Table 46. Fusing, Not Fused or Partially Fused Image (continued)
Step Actions and Questions Yes No
4.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 202
Light (Undertoned) Prints
PROBLEM: The overall image density is too light.
hc2m201F
Chapter 2. Diagnosing Problems 203
Table 47. Light (Undertoned) Prints
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v HVPS Harness (Asm-Index: 11-15, page 572)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v LVPS Assembly (Asm-Index: 12-4, page 575)
v CRU Latch (Asm-Index: 11-13, page 572)
v CRU Latch Spring (Asm-Index: 11-14, page 572)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
PRINT DENSITYa. Find the white volume knob near the left end of the EP cartridge. Ensure
that it is at the nominal position (centered between +1 and -1).b. Adjust the CONFIG MENU/DENSITY setting as needed.c. Reprint the problem image.
Is the image density normal?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
Chapter 2. Diagnosing Problems 204
Table 47. Light (Undertoned) Prints (continued)
Step Actions and Questions Yes No
2.
PAPER CONDITIONSa. Load fresh, dry paper.b. Run a Test Print.
Is the image density normal?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 3
3.
EP CARTRIDGEa. Install a new EP Cartridge.b. Reprint the problem image.
Is the image density normal?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 4
4.
DRUM GROUNDa. Remove the EP Cartridge (Asm-Index: 11-40, page 572).
b. Inspect the two Metal Grounding Springs on the rear end of the CRUGuide Assembly L (Asm-Index: 11-30, page 572). They should both havethe same shape.
Are the metal grounding springs intact, not contaminated, and notdeformed?
Go to step 5 Reform or cleanthe metalgrounding plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).
5.
CONTINUITY OF THE METAL GROUNDING PLATE
Check for the continuity between the Metal Grounding Plate and the printerframe.
Is there continuity between the Plate Grounding Plate and the printerframe?
Go to step 6 Replace the CRUGuide AssemblyR (See page 510)
Chapter 2. Diagnosing Problems 205
Table 47. Light (Undertoned) Prints (continued)
Step Actions and Questions Yes No
6.
LASER BEAM PATH
Inspect laser beam path between the ROS Assembly (Asm-Index: 11-20, page572) and the Drum.
Is the laser beam path free of obstructions?
Go to step 7 Clean the mirrorand remove anyobstructions fromthe laser beampath.
7.BTR ASSEMBLY (Asm-Index: 6-1, page 559)
Is the BTR intact and not contaminated?
Go to step 8 Replace the BTRAssembly (Seepage 466)
8.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF the printer power halfway through
the print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
drum just before the transfer area (BTR).
Is the image on the drum completely developed with sharp, black, easilyread areas?
Go to step 9 Go to “HVPS” onpage 159
9.
IMAGE TRANSFER PROCESS
Inspect the toner image on the drum immediately after the transfer area(BTR).
Is the toner image on the drum transferred completely to the paper?
Go to step 10 Go to “HVPS” onpage 159
Chapter 2. Diagnosing Problems 206
Table 47. Light (Undertoned) Prints (continued)
Step Actions and Questions Yes No
10.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 207
Residual Image
PROBLEM: There are ghost images on the page. The images may be either ghosts of the previous page orparts of the page being printed.
hc2m210F
Chapter 2. Diagnosing Problems 208
Table 48. Residual Image
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Heat Roll (Asm-Index: 9-10, page 567)
v Pressure Roll (Asm-Index: 9-15, page 567)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.REPETITIVE PRINTING
Inspect the residual images.
Was the customer printing numerous copies of the same image?
Go to step 2 Go to step 3
2.
PAPER CONDITIONa. Replace paper with fresh, dry standard paper.b. Reprint the problem image.
Do residual images still appear?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
Chapter 2. Diagnosing Problems 209
Table 48. Residual Image (continued)
Step Actions and Questions Yes No
3.EP CARTRIDGE
Install a new EP Cartridge.
Do residual images still appear?
Go to step 4 Verify the fix. Alsoverify that theproblem jobprints.
4.BTR ASSEMBLY
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Go to step 5 Replace the BTRAssembly (Seepage 466)
5.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
FUSER ASSEMBLYa. Open the Pop Up Unit.b. Remove the Fuser Assembly (See page 487).
c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll (Asm-Index: 9-10, page 567) andPressure Roll (Asm-Index: 9-15, page 567).
Are the Heat Roll and the Pressure Roll free of scratchesand contamination?
Reinstall theFuser Assembly.Go to the step 6.
Clean or replacethe FuserAssembly (Seepage 487)
Chapter 2. Diagnosing Problems 210
Table 48. Residual Image (continued)
Step Actions and Questions Yes No
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 211
Skewed Image
PROBLEM: The printed image is not parallel with the sides of the page.
hc2m212F
Chapter 2. Diagnosing Problems 212
Table 49. Skewed Image
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Pick Up Roll (Asm-Index: 6-9, page 559)
v Retard Pad Assembly (Asm-Index: 6-18, page 559)
v Front Bottom Tray (Asm-Index: 5-5, page 557)
v Rear Roll Assembly (Asm-Index: 4-11, page 555)
v Turn Roll Assembly (Asm-Index: 4-10, page 555)
v Turn Chute Assembly (Asm-Index: 3-5, page 553)
v Turn In Chute (Asm-Index: 3-4, page 553)
v Feed Roll (Asm-Index: 4-1, page 555)
v Paper Cassette (Asm: 2, page 550)
v ROS Assembly (Asm-Index: 11-20, page 572)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
Chapter 2. Diagnosing Problems 213
Table 49. Skewed Image (continued)
Step Actions and Questions Yes No
1.
PAPER FEEDa. Remove the Paper Cassette (Asm: 2, page 550).
b. Verify that the paper guides are adjusted to match the paper size.c. Reload the paper correctly in the Paper Cassette.d. Reinstall the Paper Cassette correctly.e. Open the Turn Chute Assembly (Asm-Index: 3-5, page 553) and ensure
that the Bottom Plate Assembly (Asm-Index: 2-10, page 550) is positionedcorrectly.
f. Reprint the problem image.
Is the problem still present?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.
PAPER PATH
Inspect the paper path between the feed tray and the exit tray forcontamination or obstructions.
Is the paper path free of obstructions?
Go to step 3 Removeobstructions orcontaminationfrom the paperpath.
3.
PAPER PATH ROLLSa. Inspect all of the rolls along the paper path, between the feed tray and the
exit tray, for contamination, wear, or damage.b. Ensure that the pinch rolls turn freely and that the spring pressure is even.
Are the paper path rolls free of contamination, wear, or damage?
Go to step 4 Replace thedamaged or wornroll. (See“Chapter 6.RemovalProcedures,Adjustments” onpage 394)
Chapter 2. Diagnosing Problems 214
Table 49. Skewed Image (continued)
Step Actions and Questions Yes No
4.
EP CARTRIDGEa. Install a new EP Cartridge.b. Reprint the problem image.
Is the image still skewed?
Go to step 5 Verify the fix. Alsoverify that theproblem jobprints.
5.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 215
Spots
PROBLEM: There are spots of toner randomly scattered across the page.
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Table 50. Spots
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
Chapter 2. Diagnosing Problems 216
Table 50. Spots (continued)
Step Actions and Questions Yes No
1.
EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.
Are the spots gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
2.BTR ASSEMBLY
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Go to step 3 Replace the BTRAssembly (Seepage 466)
3.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway
through the print cycle.b. Carefully remove the EP Cartridge and inspect the toner
image on the drum just before the transfer area (BTR).
Is the image on the drum completely developed, with sharp,black easily read areas and no spots?
Replace theFuser Assembly(See page 487)
Go to “HVPS” onpage 159
Chapter 2. Diagnosing Problems 217
Table 50. Spots (continued)
Step Actions and Questions Yes No
4.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 218
Streaks, Horizontal
PROBLEM: There are black lines running horizontally across the page.
Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of thisproblem, see “Operator Panel, Controller, and Power Problems” on page 135.
hc2m207F
Chapter 2. Diagnosing Problems 219
Table 51. Streaks, Horizontal
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v LVPS Assembly (Asm-Index: 12-4, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
EP CARTRIDGEa. Install a new EP Cartridge.b. Reprint the problem image.
Are the horizontal streaks gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
2.
DRIVE TRANSMISSION
Perform “53 ERROR CALL FOR SERVICE” on page 114 and fix the problemsif any.
Is the rotation of the Main Motor (Asm-Index: 10-6, page 570) transmittedto all the rolls?
Go to step 3 Follow theinstructions in “53ERROR CALLFOR SERVICE”on page 114.
Chapter 2. Diagnosing Problems 220
Table 51. Streaks, Horizontal (continued)
Step Actions and Questions Yes No
3.
DRUM GROUNDa. Remove the EP Cartridge.b. Inspect the metal grounding plate on the rear end of the CRU Guide
Assembly R (Asm-Index: 11-31, page 572).
Is the metal grounding plate intact, not contaminated and not deformed?
Go to step 4 Reform or cleanthe metalgrounding plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).
4.
CONTINUITY OF THE METAL GROUNDING PLATE
Check for the continuity between the Metal Grounding Plate and the printerframe.
Is there continuity between the Grounding Plate and the Printer Frame?
Go to step 5 Replace the CRUGuide AssemblyR (See page 510)
5.BTR ASSEMBLY (Asm-Index: 6-1, page 559)
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Go to step 6 Replace the BTRAssembly (Seepage 466)
6.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through print
cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
Drum just before the transfer area (BTR).
Is the image on the Drum completely developed; with sharp, black, easilyread areas and no horizontal streaks?
Go to step 7 Go to “HVPS” onpage 159
Chapter 2. Diagnosing Problems 221
Table 51. Streaks, Horizontal (continued)
Step Actions and Questions Yes No
7.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
IMAGE TRANSFER PROCESS
Inspect the toner image on the Drum immediately after thetransfer area (BTR).
Was the toner image on the Drum transferred completely tothe paper along with horizontal streaks?
Replace theFuser Assembly(See page 487)
Replace the BTRAssembly (Seepage 466)
8.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 222
Streaks, Vertical
PROBLEM: There are black lines running vertically along the page.
Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of thisproblem, see “Operator Panel, Controller, and Power Problems” on page 135.
hc2m206F
Chapter 2. Diagnosing Problems 223
Table 52. Streaks, Vertical
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v MCU PWB (Asm-Index: 12-8, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.
Are the vertical streaks gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 2
2.LASER BEAM PATH
Inspect the laser beam path between the ROS Assembly and the Drum.
Is the laser beam path free of obstructions?
Go to step 3 Remove anyobstructions fromthe laser beampath.
3.BTR ASSEMBLY
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Go to step 4 Replace the BTRAssembly (Seepage 466)
Chapter 2. Diagnosing Problems 224
Table 52. Streaks, Vertical (continued)
Step Actions and Questions Yes No
4.
PAPER PATH
Inspect the paper path, between feed and exit, for contamination orobstructions.
Is the paper path free of obstructions?
Go to step 5 Removeobstructions orcontaminationfrom the paperpath
5.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567)and PRESSURE ROLL (Asm-Index: 9-15, page 567)
a. Open the Pop Up Unit.b. Open the Fuser Cover Assembly and the Fuser Rear
Assembly (Asm-Index: 8-10, page 564).
c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll and the Pressure Roll.
Are the Heat Roll and the Pressure Roll free of scratchesand contamination?
Go to step 6 Replace theFuser Assembly(See page 487)
Chapter 2. Diagnosing Problems 225
Table 52. Streaks, Vertical (continued)
Step Actions and Questions Yes No
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 226
Unusual Patterns
PROBLEM: Light gray background, with large areas covered with random dark spots. This is usually causedby charging problems during printing.
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Table 53. Unusual Patterns
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559), unseated or bad
v Dirty or bent contacts on the EP Cartridge or BTR Assemblyv HVPS (Asm-Index: 12-11, page 575)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
Chapter 2. Diagnosing Problems 227
Table 53. Unusual Patterns (continued)
Step Actions and Questions Yes No
v Exchange the suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 228
Voids
PROBLEM: There are areas of the image that are extremely light or missing. These missing areas formlocalized spots to small areas of the page.
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Table 54. Voids
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
Chapter 2. Diagnosing Problems 229
Table 54. Voids (continued)
Step Actions and Questions Yes No
1.
PAPER CONDITIONSa. Load fresh, dry standard paperb. Reprint the problem image.
Is the problem still present?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.
EP CARTRIDGEa. Install a new EP Cartridge.b. Reprint the problem image.
Note: If the new EP cartridge fixes the problem, the problem may have beencaused by toner clumping in the old EP cartridge. This sometimes happens inhot and humid environments. Shaking the old EP cartridge to break up thetoner clumps may fix the problem. Use caution when shaking the EP cartridgeso that toner is not expelled.
Is the problem still present?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
3.
IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through the
print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
drum just before the transfer area (BTR).
Is the image on the drum completely developed; with sharp, black easilyread areas and no spot deletions?
Go to step 4 Go to “HVPS” onpage 159
4.
IMAGE TRANSFER PROCESS
Inspect the toner image on the drum immediately after the transfer area(BTR).
Is the toner image on the drum transferred completely to the paper?
Replace theFuser Assembly(See page 487)
Replace the BTRAssembly (Seepage 466)
Chapter 2. Diagnosing Problems 230
Table 54. Voids (continued)
Step Actions and Questions Yes No
5.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 231
Voids, Horizontal
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands thatrun horizontally across the page, parallel with the direction of paper travel.
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Chapter 2. Diagnosing Problems 232
Table 55. Voids, Horizontal
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v HVPS (Asm-Index: 12-11, page 575)
v CRU Guide Assembly L (Asm-Index: 11-30, page 572)
v CRU Guide Assembly R (Asm-Index: 11-31, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v Fuser Assembly (Asm-Index: 8-1, page 564)
v Main Gear Assembly (Asm-Index: 10-10, page 570)
v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
v Registration Clutch Assembly (Asm-Index: 10-9, page 570)
v Rear Roll Assembly (Asm-Index: 4-11, page 555)
v Turn Roll Assembly (Asm-Index: 4-10, page 555)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
1.
PAPER CONDITIONSa. Load fresh, dry standard paper.b. Reprint the problem image.
Does the problem appear?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
Chapter 2. Diagnosing Problems 233
Table 55. Voids, Horizontal (continued)
Step Actions and Questions Yes No
2.
MAIN MOTOR (Asm-Index: 10-6, page 570) and DRIVE TRANSMISSION
a. Refer to “53 ERROR CALL FOR SERVICE” on page 114 for causes ofpossible motor problems.
b. Reprint the problem image.
Does the problem appear?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
3.EP CARTRIDGE
Install a new EP Cartridge.
Are the horizontal band deletions gone?
Verify the fix. Alsoverify that theproblem jobprints.
Go to step 4
4.BTR ASSEMBLY (Asm-Index: 6-1, page 559)
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Go to step 5 Replace the BTRAssembly (Seepage 466)
5.
IMAGE DEVELOPMENT PROCESSa. Generate a print and switch OFF printer power halfway through the print
cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the
drum just before the transfer area (BTR).
Is the image on the drum completely developed, with sharp, black, easilyread areas and no horizontal band deletions?
Go to step 6 Go to “HVPS” onpage 159
Chapter 2. Diagnosing Problems 234
Table 55. Voids, Horizontal (continued)
Step Actions and Questions Yes No
6.
CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.
IMAGE TRANSFER PROCESS
Inspect the toner image on the drum immediately after thetransfer area (BTR).
Was the toner image on the drum transferred completely tothe paper?
Replace theFuser Assembly(See page 487).
Go to step 7.
Go to “HVPS” onpage 159
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 235
Voids, Vertical
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands thatrun vertically along, in the direction of paper travel.
hc2m204F
Table 56. Voids, Vertical
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v EP Cartridge (Asm-Index: 11-40, page 572)
v BTR Assembly (Asm-Index: 6-1, page 559)
v Transport Chute Assembly (Asm-Index: 6-2, page 559)
v ROS Assembly (Asm-Index: 11-20, page 572)
v MCU PWB (Asm-Index: 12-8, page 575)
v Fuser Assembly (Asm-Index: 8-1, page 564)
Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?
Chapter 2. Diagnosing Problems 236
Table 56. Voids, Vertical (continued)
Step Actions and Questions Yes No
1.
PAPER CONDITIONSa. Load fresh, dry standard paper.b. Reprint the problem image.
Is the problem still present?
Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.
2.
EP CARTRIDGE (Asm-Index: 11-40, page 572)
a. Install a new EP Cartridge.b. Reprint the problem image.
Is the problem still present?
Go to step 3 Verify the fix. Alsoverify that theproblem jobprints.
3.LASER BEAM PATH
Inspect the laser beam path between the ROS Assembly and the Drum.
Is the laser beam path free of obstructions?
Go to step 4 Remove anyobstructions fromthe laser beampath.
4.
PAPER PATH
Inspect the paper path, between feed and exit, for contamination orobstructions.
Is the paper path free of obstructions?
Go to step 5 Removeobstructions orcontaminationfrom the paperpath.
5.BTR ASSEMBLY (Asm-Index: 6-1, page 559)
Inspect the BTR Assembly for contamination and wear.
Is the BTR free of contamination and wear?
Replace theFuser Assembly(See page 487)
Replace the BTRAssembly (Seepage 466)
Chapter 2. Diagnosing Problems 237
Table 56. Voids, Vertical (continued)
Step Actions and Questions Yes No
6.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Chapter 2. Diagnosing Problems 238
Status MessagesPrinter status messages are listed alphabetically.
COLD RESET A4Meaning : The printer is powering up and resetting all menu values to the factory defaults. The A4 papergroup is the default.
Action : None required; however, restore any unique settings for the printer (such as the default tray).
COLD RESET LTRMeaning : The printer is powering up and resetting all menu values to the factory defaults. The LTRpaper group is the default.
Action : None required; however, restore any unique settings for the printer (such as the default tray).
CONTEXT SAVE ADJUSTEDMeaning : The printer is configured to use the context saving option (PCL SAVE and PS SAVE under theMemconfig Menu); however, due to a configuration change, the printer no longer has enough memory tosupport context saving.
Action : Press Continue . To restore context saving, have the customer add more memory to the printer.
CONTEXT SAVE CHANGEMeaning : The values for the PCL SAVE or PS SAVE items under the Memconfig Menu have beenchanged.
Action : Press the Continue key to accept the new values and continue printing.
DSK FMT RESTARTMeaning : The printer is restarting to include the hard drive in its configuration.
Action : None required.
Chapter 2. Diagnosing Problems 239
+ FORMAT DISK/- IGNORE DISKMeaning : You are powering up with an unformatted hard drive, or you selected the FORMAT DISKaction on the Test Menu.
Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocontinue as if there were no hard drive installed.
FLUSHING...Meaning : The printer is canceling a PCL5e or PostScript job.
Action : None required.
FORMATTINGMeaning : The printer is formatting the hard disk drive.
Action : None required.
F/W xxxxxxxMeaning : Firmware error (xxxxxxx can be any alphanumeric value).
Action : Power the printer off, wait ten seconds, and power the printer back on. If problems persist, callfor technical support.
Note: When firmware errors occur, the printer might also print an error page. If the printer does print anerror page, save it so you can tell technical support.
I/O INITIALIZINGMeaning : The network interface card is initializing.
Action : Normally none. If the message remains on the display for more than 5 minutes and nothingprints, go to “Ethernet / Token-Ring NIC Printing Problems” on page 150 or “Twinax / Coax NIC PrintingProblems” on page 179.
Note: If more than one Network Interface Card is installed, remove them one at a time to determinewhich card is causing the problem.
Chapter 2. Diagnosing Problems 240
IBM INFOPRINT 20Meaning : The printer power has just been switched on.
Action : Normally none. If the message remains on the display and nothing prints, wait three minutes toverify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to“Operator Panel, Controller, and Power Problems” on page 135.
- IGNORE DISK/+ FORMAT DISKMeaning : You are powering up with an unformatted hard drive, or you selected the FORMAT DISKaction on the Test Menu.
Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocontinue as if there were no hard drive installed.
IPDS COAXMeaning : The printer is receiving IPDS data through the coax interface.
Action : None required.
IPDS ETHERNETMeaning : The printer is receiving IPDS data through the Ethernet interface.
Action : None required.
IPDS TOKEN-RINGMeaning : The printer is receiving IPDS data through the token-ring interface.
Action : None required.
IPDS TWINAXMeaning : The printer is receiving IPDS data through the twinax interface.
Action : None required.
JOB QUEUEDMeaning : An informational page is queued for printing.
Action : If the online indicator is off, press the Online key.
Chapter 2. Diagnosing Problems 241
KEY NOT VALIDMeaning : You pressed a key that is not valid.
Action : Press another key. In some instances, you may need to press the Online key to use other keyssuch as the Menu key.
MEMCONFIG CHANGEMeaning : You changed a value on the Memory Configuration (Memconfig) Menu.
Action : Press the Continue key to reboot the printer so the new value can take effect.
MEMCONFIG CHANGE 1200 DPI UNAVAILMeaning : You turned on context saving (PCL SAVE or PS SAVE) on the Memory Configuration(Memconfig) Menu. 1200 dpi emulation is no longer available because there is not enough memory.
Action : Press the Continue key to reboot the printer so the new value can take effect. To enable 1200DPI emulation, Have the customer add more memory or turn context saving off.
MENU LOCKEDMeaning : The system administrator has locked the menu. You can view menu settings but you cannotchange them.
Action : None required.
MRT COMPRESSIONMeaning : The printer is compressing the page image it is printing because it does not have enoughmemory to print the page without compression.
Action : None required.
NEW VALUES AT NEXT BOUNDARYMeaning : You have taken the printer offline while a job was printing to change a menu value. The newvalue might not take effect until the next “job boundary”. Different data streams, in particular SCS, definejob boundaries in different ways, so it may take a while for the new value to take effect.
Action : None required. If problems occur, make sure you take the printer offline to change menu valuesonly when no jobs are printing (the printer is in READY state).
Chapter 2. Diagnosing Problems 242
NONIPDS COAXMeaning : The printer is receiving SCS or DSC/DSE data through the coax interface.
Action : None required.
NONIPDS TWINAXMeaning : The printer is receiving SCS data through the twinax interface.
Action : None required.
OFFLINEMeaning : The printer is offline.
Action : Press the Online key to make the printer active.
ONLINE HEX PRTMeaning : The printer is performing a hexadecimal dump.
Action : None required.
PAGES:nnnnMeaning : This is a response to the PAGE COUNT item on the Machine Info Menu, where nnnn is thenumber of pages the printer has printed.
Action : None required.
PCL ETHERNETMeaning : The printer is receiving PCL5e data through the Ethernet interface.
Action : None required.
PCL PARALLELMeaning : The printer is receiving PCL5e data through the parallel interface.
Action : None required.
PCL TOKEN-RINGMeaning : The printer is receiving PCL5e data through the token-ring interface.
Chapter 2. Diagnosing Problems 243
Action : None required.
PJL PARALLELMeaning : The printer is receiving or sending PJL information through the parallel interface.
Action : None required.
PLEASE WAITMeaning : The printer is processing data and cannot immediately respond to a request.
Action : Wait until the message clears. If the message remains and processing on the host appears tohave stopped, power off the printer, wait ten seconds, and then power on the printer.
POWER SAVER ONMeaning : The printer is in power-saving mode and has temporarily shut off power to certain of itscomponents. Power will be restored as soon as a job is submitted.
Action : None required.
PS ETHERNETMeaning : The printer is receiving PostScript data through the Ethernet interface.
Action : None required.
PS PARALLELMeaning : The printer is receiving PostScript data through the parallel interface.
Action : None required.
PS TOKEN-RINGMeaning : The printer is receiving PostScript data through the token-ring interface.
Action : None required.
READYMeaning : The printer is ready to receive data.
Action : None required.
Chapter 2. Diagnosing Problems 244
+ REALLY FORMA T / - IGNORE DISKMeaning : You have asked to format the hard drive.
Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocancel the formatting.
RECONFIGURING MEMORYMeaning : The printer has received a print job that requires it to adjust memory settings for the currentpage.
Action : No action is required. The printer reconfigures its memory settings to print the current page.Afterward, its settings revert to normal.
RESETTING PRINTERMeaning : The printer is resetting to its defaults.
Action : None required.
RESTORING DEFAULTSMeaning : The printer is restoring the defaults.
Action : None required.
SWITCHING TO IPDSMeaning : The printer is switching to IPDS.
Action : None required.
SWITCHING TO PCLMeaning : The printer is switching to PCL5e.
Action : None required.
SWITCHING TO PSMeaning : The printer is switching to PostScript.
Action : None required.
Chapter 2. Diagnosing Problems 245
WAIT FOR IDLE PRINTERMeaning : You attempted to print from the Test Menu while the printer was processing PCL, PostScript,or IPDS data.
Action : When a port timeout occurs for the data stream (PCL5e, PostScript, or IPDS), the READYmessage appears on the operator panel. Wait for the READY message and then try printing again.
WARMING UPMeaning : The printer is warming up. When it is warm, it displays the READY message.
Action : None required. If the message seems to appear too frequently, change the value for thepower-saving mode to a larger value. If the message remains on the display and nothing prints, waitthree minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the messagepersists, go to “Operator Panel, Controller, and Power Problems” on page 135.
Chapter 2. Diagnosing Problems 246
Chapter 3. Diagnostic ToolsOperator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249Configuration Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Running Paper Path Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251Printing a Test Matrix Page from the DIAGNOSTICS MENU . . . . . . . . . . . . . . . . . . . . . . . .251Printing a Test Matrix Page Without the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
Cold Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253MACHINE INFO MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254
Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256DIAGNOSTICS MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
D01 TEST PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257D11 CHECK SUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258D13 FUSER TEMP (Current Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259D21 SENSOR TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261D23 TEST FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267D41 CLUTCH TR (Turn Roll Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269D43 CLUTCH REG (Registration Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271D44 HCF UP (Tray Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273D45 HCF DOWN (Tray Lowers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275D50 SOL TRAY A (Auxiliary Tray Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283D60 DRIVE MOTOR MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
© Copyright IBM Corp. 1998 247
D63 MOTOR D CW (Duplex Motor Runs CW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287D64 MOTOR D CCW (Duplex Motor Runs CCW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289D68 HCF MOTOR (HCF Transport Motor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
FACTORY ADJ MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293A01 Reg Top 1 (Leading Edge Registration, Tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .296A03 Reg Top 2 (Leading Edge Registration, Tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .297A05 Reg Top 3 (Leading Edge Registration, Tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .298A07 Reg Top A (Leading Edge Registration, Aux. Tray) . . . . . . . . . . . . . . . . . . . . . . . . . .299A09 Reg Left 1 (Left Edge Registration, Tray 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300A11 Reg Left 2 (Left Edge Registration, Tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301A13 Reg Left 3 (Left Edge Registration, Tray 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302A15 Reg Left A (Left Edge Registration, Aux. Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . .303A21 Fuser Temp (Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304S/N = 00-00000 (Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Menu Items Not Described . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Chapter 3. Diagnostic Tools 248
Operator Control Panel
v Press Online to toggle the printer online or offline.v Press Menu to scroll through menus.v Press Item to scroll through menu items.v Press Value to scroll through values for a menu item.v Press Shift to reverse the scroll direction.v Press Enter to accept a menu item or value selection.
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Configuration Page1. Press Online to take the printer offline.2. Press Menu . The message TEST MENU appears.3. Press Item . The message CONFIG PAGE appears in the second line.4. Press Enter to print the configuration page.
Notes:1. The configuration pages print from the PAPER MENU/SOURCE.2. To print continuous configuration pages, press Item until CONTINUOUS TEST appears, then press Enter .
To stop, press Cancel Print and wait for up to 10 pages.3. To print duplex continuous configuration pages, set PAPER MENU/DUPLEX=ON.4. If the serial number printed on the configuration page does not match the printer serial number, see
“S/N = 00-00000 (Serial Number)” on page 305. (See Figure 5 on page 363 for the location of the printerserial number.)
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Test Prints
Running Paper Path Test Prints1. Press Online to take the printer offline.2. Press Menu to select PAPER MENU.3. Press Item to scroll to the desired input paper SOURCE.4. Press Enter . An asterisk (*) appears next to your choice.5. Press Menu to scroll to the TEST MENU.6. Press Item to scroll to the desired test page.v CONFIG PAGE prints the menu settings.v DEMO includes shading.v CONTINUOUS TEST prints multiple configuration pages (press Cancel Print to stop printing after 10 or
so pages).7. Press Enter to print the test page.
Printing a Test Matrix Page from the DIAGNOSTICSMENUGo to “D01 TEST PRINT” on page 257.
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Printing a Test Matrix Page Without the ControllerThis procedure prints a test page without a controller installed. It provides a ground spike to the test printsignal (/TESTPRINT) at MCU P23, which creates the test page. The procedure can help isolate MCU or printengine problems versus controller problems (if the test page prints, the MCU and the print engine arefunctional). It can be used for adjusting print registration from Tray 1.1. Power OFF the printer.2. Remove the controller.3. Locate P23, which is the 2-pin connector near the upper right corner of the MCU (there is no cable
attached).4. Close the printer covers. Ensure that tray 1 has paper and is installed.5. Connect a jumper to the pins of P23.
Note: If you do not have a jumper, you can use one from a Controller SIMM. Before removing a jumper,note its location for reinstallation.
6. Power ON the printer. The main motor and the fan turn on as the MCU tests the printer.7. If the MCU and the print engine are operating correctly, a test page prints within two minutes.
Note: If a test page does not print, ensure that the jumper in P23 is secure. Retry the procedure. If a testpage still does not print, ensure that there are no error conditions, such as an empty paper tray,paper jam, or open covers.
8. Test pages will continue to print (simplex) until the jumper is removed. If the duplex option is installed,removing and replacing the jumper will print test pages (duplex) until the jumper is removed again.
9. If you used a jumper from a Controller SIMM, reinstall the jumper on the Controller SIMM.
Note: MCU-detected errors, such as a fan problem, cause the printer to stop before printing a test page.With the controller installed, these MCU-detected errors display with error codes of 5n (See“Chapter 2. Diagnosing Problems” on page 37).
Chapter 3. Diagnostic Tools 252
Cold ResetThe following procedure resets all values in printer NVRAM to factory defaults, and clears the error log.1. Print a configuration page (see “Configuration Page” on page 250).
2. Switch off printer power.3. Do the following:
For the LTR (letter) paper group:Press and hold the Online key while switching on printer power. COLD RESET LTR appears in themessage display.For the A4 paper group:Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in themessage display.
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MACHINE INFO MENU
Error LogTo display the last 10 error message entries:1. Press Online to take the printer offline.2. Press Menu to select the MACHINE INFO Menu.3. Press Item to select ERROR LOG.4. Press Enter to display the most recent entry.
Note: ″Common″ errors, such as COVER OPEN, are not logged.5. Press Value to scroll through the list.6. Press Shift and Enter at the same time to clear the error log.
Note: The Error Log can also be printed by “Running Paper Path Test Prints” on page 251.
Chapter 3. Diagnostic Tools 254
CountersThe Machine Info Menu also displays information about printer supply usage. From the Machine Info Menu,select the desired counter:
Machine Info Menu Item Description
PAGE COUNT Displays the number of pages the printer has printed.
ERROR LOG Displays the error log. Use the Value key to scroll through the list.
TONER COUNTER Displays the EP cartridge count. IBM recommends resetting this counterwhenever you change toner cartridges. To reset the counter:1. Simultaneously press the Shift and Value keys.2. Press the Enter key.
FUSER COUNTER Displays the fuser counter. IBM recommends resetting this counterwhenever you change the usage kit. To reset the counter:1. Simultaneously press the Shift and Value keys.2. Press the Enter key.
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Service ModeThe service mode consists of two service menus: the DIAGNOSTICS MENU and the FACTORY ADJ MENU.
To display a service menu:1. Power OFF the printer.2. Turn on the printer power while pressing Item and Value simultaneously for a few seconds. Wait until the
message DIAGNOSTICS MENU appears.3. Press Menu to select the service menu (DIAGNOSTICS MENU or FACTORY ADJ MENU).
To select a test or item in the DIAGNOSTICS MENU or FACTORY ADJ MENU:1. Press Item to scroll through the tests or items.2. Press Enter when you reach the test or item you want to run.3. Press Cancel Print to temporarily stop an action test, such as a ‘motor running’ test. Then press Enter to
restart the same test.
Chapter 3. Diagnostic Tools 256
DIAGNOSTICS MENUD01 TEST PRINT
Prints a test matrix page from Tray 1. Before performing this test, make sure Tray 1 has paper.
There is no error reporting with this test.
To run D01 TEST PRINT:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D01 TEST PRINT displays.4. Press Enter to begin printing from Tray 1.5. After the print completes, press Item to step to another item in the DIAGNOSTICS MENU
See “Test Prints” on page 251 for more information on running test prints.
Output Tests
The output tests fall into two groups:v Displaying the fuser temperature control setting and the current fuser temperaturev Actuating components
Once the unit starts executing an output test, the only diagnostic codes accessible are those for output tests.It is thus impossible to break out of the output test mode.
Turning the interlock switch off is another way of terminating the display of the accumulated print count.
The output tests permit the parallel operation of multiple components.
Chapter 3. Diagnostic Tools 257
D11 CHECK SUM
The diagnostic test displays the checksum of the printer ROM. The LCD displays the checksum as a four-digitnumber.
To run D11 CHECK SUM:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D11 CHECK SUM displays.4. Press Enter to begin test.5. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
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D13 FUSER TEMP (Current Setting)
Diagnostic code D13 executes immediatly if any of the other output tests is being executed.
To run D13 FUSER TEMP:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the test or items.3. Stop pressing Item when D13 FUSER TEMP displays.4. Press Enter to begin test. A screen displays the factory adjustment fuser temperature (SET) and the actual
fuser temperature (ACT) in HEX.
Note: If you need to change the SET value, go to “A21 Fuser Temp (Adjustment)” on page 304.
5. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Note: Because the fuser is constantly moving through a range of temperatures (warming and cooling), it isnormal for the fuser temperature to change as you run the test.
Check the two-digit hexadecimal number that appears in the lower right corner of the LCD. It is a code thatgives the two running temperatures for controlling the fuser temperature: the normal temperature and the hightemperature.
Chapter 3. Diagnostic Tools 259
The following chart lists the temperature code settings and the corresponding temperature ranges.Table 57. Fuser Temperature Codes
Code Temperature Code Range
[Normal Temp./High Temp.] (Hexadecimal)
Fuser Temperature
[Normal Temp./High Temp.]
(°C) Approximate
0 C2 / B2 155 / 172
1 BF / AF 158 / 175
2 BC / AC 162 / 178
3 B9 / A9 165 / 181
4 B6 / A6 168 / 184
5 B3 / A3 171 / 187
6 B0 / A0 174 / 190
7 AD / 9D 177 / 193
8 AA / 9A 180 / 196
9 A7 / 97 183 / 199
A A4 / 94 186 / 202
B A1 / 91 189 / 205
C 9E / 8E 192 / 208
D 9B / 8B 195 / 211
E 98 / 88 198 / 215
F 95 / 85 201 / 218
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D21 SENSOR TEST
This diagnostic test checks the function of sensors and switches within the printer.
Note: The toner sensor input test does not work if the interlock switch is off.
To run D21 SENSOR TEST:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Press Item to step through the tests or items.3. Stop pressing Item when D21 SENSOR TEST displays.4. Press Enter to begin test.5. Manually activate and deactivate the sensor or the switch you want to test. If a sensor or switch is
functioning correctly, ″SENSOR OK″ displays. If the sensor is not functioning correctly, ″Activate Sensor″continues to display.
6. To exit this test activate a sensor that functions correctly, then press Item to step to another item in theDIAGNOSTICS MENU.
Note: See Figure 3 on page 265 and Figure 4 on page 266 for the locations of the following items.
Chapter 3. Diagnostic Tools 261
Items Tested and Relevant Procedures:
Item Procedure
Interlock switch With the EP cartridge removed, open and close the pop up unit to turn the interlockswitch off and on.
Fuser cover switch Open and close the fuser cover to turn the fuser cover switch off and on.
CRU switch in CRU sensor assembly(See Caution <2–33>).
First disconnect either the P/J12 connector on the MCU PWB or the P/J112 connectorin the ROS assembly. With the pop up unit open, use a small screwdriver or otherimplement to turn the CRU sensor assembly actuator on and off.
Feeder PWB paper size switches fortrays 1-3
Use your hand or other means to move the size actuators and thus turn the feederPWB paper size switches on and off.
AUX tray no paper sensor Use your hand or other means to move the AUX tray no paper actuator to switch theAUX tray no paper sensor between its no paper and paper positions.
Tray 1, 2, or 3 no paper sensor Use your hand or other means to move the tray 1, 2, or 3 no paper actuator to switchthe tray 1, 2, or 3 no paper sensor between its no paper and paper positions.
Registration sensor Use a sheet of paper or other means to move the registration actuator to switch theregistration sensor between its no paper and paper positions. You may need aflashlight to see the actuator in the small rectangular recess at the center of the areabehind the toner cartridge.
Exit sensor Open the fuser cover and the fuser jam access cover. Use a sheet of paper or othermeans to move the exit actuator to switch the exit sensor between its no paper andpaper positions. The sensor is part of the fuser.
Full stack sensor Use your hand or other means to move the full stack actuator to switch the full stacksensor between its no paper and paper positions. The sensor is ignored if the Duplexoption is installed.
Chapter 3. Diagnostic Tools 262
Item Procedure
Toner sensor Disconnect P/J171 at the CRU sensor assembly or P/J17 at the MCU; this ensures thatthe laser will not turn on if you accidentally activate the CRU sensor. If the duplexoption is installed, you can open the duplex cover to disable the laser. With theinterlock switch on, install and remove an EP cartridge containing toner, or activate witha non-magnetic metal tool.
Duplex cover switch 1 With the duplex unit lower cover closed, open and close the duplex unit upper cover toturn the duplex cover switch 1 on and off.
Duplex cover switch 2 With the duplex unit upper cover closed, open and close the duplex unit lower cover toturn the duplex cover switch 2 on and off.
Duplex pass sensor Open the duplex unit upper cover. Use your hand or other means to move the duplexpass sensor actuator and thus turn the duplex pass sensor on and off.
DUP stack sensor Use your hand or other means to move the DUP stack actuator to switch the DUPstack sensor between its no paper and paper positions.
HCF Exit sensor Open the HCF rear cover. Override the left and right cover open switches. Cover anduncover the sensor.
HCF Lower position sensor Cannot be tested with D21.
HCF size sensor Remove the left hand side plate. Depress the switch.
HCF Near empty sensor Remove the front cover. Depress the switch.
HCF left hand cover open switch Open the HCF rear cover on the left side only. Opening the cover will change the stateof the switch.
HCF right hand cover open switch Open the HCF rear cover on the right side only. Opening the cover will change thestate of the switch.
HCF tray set sensor 1 With the HCF drawer pulled out and the elevator in the down position, depress both thetray set sensor 1 and tray set sensor 2. Activate D21 and release tray set sensor 1.(Do not allow the bottom plate to rise near the top of the drawer. Damage will occur bynot coming in contact with the upper limit switch).
Chapter 3. Diagnostic Tools 263
Item Procedure
HCF tray set sensor 2 Cannot test with D21
Upper limit switch With the elevator in the down position, open the front door and activate D21. Reachinside and push up on the feed roller bracket until you hear a click. This will activatethe upper limit switch.
HCF paper level sensor Push the actuator up into the paper level sensor.
HCF paper out sensor Push up on the paper out sensor. The paper out actuator and sensor are part of thefeed roller bracket assembly.
Chapter 3. Diagnostic Tools 264
Full StackSensor
Exit SensorCRU Switch
RegistrationSensorToner
Sensor
MSI (Aux)No Paper Sensor
Fuser Assembly
Full StackSensor
Full Stack Actuator
Exit RollAssembly
Exit Sensor
Exit Actuator
Exit ChuteRoll
Pinch Roll
RegistrationSensor
RegistrationActuator
Pick UpRoll
Metal RegistrationRoll
Rubber RegistrationRoll
hc2m979F
Control Assembly(Console Assembly)
Figure 3. Sensor and Switch Locations I
Chapter 3. Diagnostic Tools 265
CST No Paper Sensor
Interlock Switch
Fuser Cover Switch
Paper SizeSwitch
Feeder PWB
Interlock ActuatorFuser Cover Pop Up Cover Assembly
CST No Paper Sensor
Feed Roll
CST No Paper Actuator
Paper SizeSwitch
Size Actuator
Size Cam
FRONT
hc2m980F
Fuser Cover Switch Interlock Switch
Figure 4. Sensor and Switch Locations II
Chapter 3. Diagnostic Tools 266
D23 TEST FAN
This diagnostic test runs the fan at high speed.
MCU
Fan
hc2m993F
FRONT
Chapter 3. Diagnostic Tools 267
To run D23 TEST FAN:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D23 TEST FAN displays.4. Press Enter to begin test.5. Verify that when you press Enter , the fan is running at high speed.
Verify that the fan is running at high speed from the noise that it makes or from the wind pressure.6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Note: The fan runs at low speed whenever the power is on. It switches to high speed when the main motor ison. This test switches the fan from low speed to high speed.
Chapter 3. Diagnostic Tools 268
D41 CLUTCH TR (Turn Roll Clutch)
This diagnostic code tests all the Electromagnetic Turn Roll Clutches (tray 1, 2, and 3).
MCU PWB
ElectromagneticTurn Roll Clutch(Tray 1)
ElectromagneticTurn Roll Clutch(Tray 2)
ElectromagneticTurn Roll Clutch(Tray 3)hc2m985F
FRONT
Chapter 3. Diagnostic Tools 269
To run D41 CLUTCH TR:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D41 CLUTCH TR displays.4. Press Enter to begin test.5. Verify that when you press Enter , the turn roll clutch actuates.
Confirm clutch operation by listening for the slight click of operation or manually rotating the correspondingdriven rollers (rubber registration roll and turn roll assembly) to confirm that they are no longer free, butfixed to the drive system.
6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 270
D43 CLUTCH REG (Registration Clutch)
This diagnostic code tests the Registration Clutch Assembly.
MCU PWB
Registration Clutch Assembly
MetalRegistration Roll
hc2m986F
FRONT
Chapter 3. Diagnostic Tools 271
To run D43 CLUTCH REG:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D43 CLUTCH REG displays.4. Press Enter to begin test.5. Verify that when you press Enter , the registration clutch actuates.
Confirm clutch operation by listening for the slight click of operation or manually rotating the correspondingdriven rollers (rubber registration roll and turn roll assembly) to confirm that they are no longer free, butfixed to the drive system.
6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 272
D44 HCF UP (Tray Lifts)
This tests the lifting of the bottom plate.
hc2m026F
2
1
1
Chapter 3. Diagnostic Tools 273
To run D44 HCF UP, perform the following:
1. Enter the DIAGNOSTICS MENU (see “Service Mode” on page 256).
2. Repeatedly press Item , stepping through the menu until D44 HCF UP displays.3. Press Enter ; you should hear the elevator motor run.4. To view the travel of the bottom plate, open the HCF rear cover and manually close the left and right hand
cover open switches.Press Cancel Print to stop the test; press Enter to restart the test.
Chapter 3. Diagnostic Tools 274
D45 HCF DOWN (Tray Lowers)
This tests the lowering of the bottom plate.
hc2m026F
2
1
1
Chapter 3. Diagnostic Tools 275
To run D45 HCF DOWN, perform the following:
1. Enter the DIAGNOSTICS MENU (see “Service Mode” on page 256).
2. Repeatedly press Item , stepping through the menu until D45 HCF DOWN displays.3. Press Enter ; you should hear the elevator motor run.4. To view the travel of the bottom plate, open the HCF rear cover and manually close the left and right hand
cover open switches.Press Cancel Print to stop the test; press Enter to restart the test.
Chapter 3. Diagnostic Tools 276
D50 SOL TRAY A (Auxiliary Tray Feed Solenoid)
This diagnostic code tests the Auxiliary Tray paper pick solenoid. The solenoid picks for approximately 0.5seconds. After that interval, the solenoid automatically turns off.
MCU PWB
Pick Up Solenoid hc2m983F
Chapter 3. Diagnostic Tools 277
To run D50 SOL TRAY A:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D50 SOL TRAY A displays.4. Press Enter to begin test.5. Verify that when you press Enter , the AUX feed solenoid actuates.
Confirm solenoid operation by listening for the slight click of operation or watching for the rotation of thecorresponding shaft or roller when the power is turned off and on after the execution of the diagnosticroutine.
6. The solenoid may now be in a pre-pick condition. Remove paper from the Auxiliary Tray and switch theprinter off, and then on to reset the solenoid (if you do not remove paper you may get a 24 PAPER JAMwhen the motor is tested during power up).
Chapter 3. Diagnostic Tools 278
D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid)
This diagnostic test actuates the Tray1 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. Afterthat interval, the solenoid automatically turns off.
Feed Solenoid
Feed Solenoid
Feed Solenoid
MCU PWB
hc2m984F
FRONT
D51
D52
D53
Chapter 3. Diagnostic Tools 279
To run D51 SOLENOID TRAY1:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D51 SOLENOID TRAY1 displays.4. Press Enter to begin test.5. Verify that when you press Enter , the Tray 1 feed solenoid actuates.
Confirm solenoid operation by listening for the slight click of operation or watching for the rotation of thecorresponding shaft or roller when the power is turned off and on after the execution of the diagnosticroutine.
6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 280
D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid)
This diagnostic test actuates the Tray2 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. Afterthat interval, the solenoid automatically turns off.
Feed Solenoid
Feed Solenoid
Feed Solenoid
MCU PWB
hc2m984F
FRONT
D51
D52
D53
Chapter 3. Diagnostic Tools 281
To run D52 SOLENOID TRAY2:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D52 SOLENOID TRAY2 displays.4. Press Enter to begin test.5. Verify that when you press Enter , the Tray 2 feed solenoid actuates.
Confirm solenoid operation by listening for the slight click of operation or watching for the rotation of thecorresponding shaft or roller when the power is turned off and on after the execution of the diagnosticroutine.
6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 282
D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid)
This diagnostic test actuates the Tray3 Feed Solenoid. The solenoid picks for approximately 0.5 seconds. Afterthat interval, the solenoid automatically turns off.
Feed Solenoid
Feed Solenoid
Feed Solenoid
MCU PWB
hc2m984F
FRONT
D51
D52
D53
Chapter 3. Diagnostic Tools 283
To run D53 SOLENOID TRAY3:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D53 SOLENOID TRAY3 displays.4. Press Enter to begin test.5. Verify that when you press Enter , the Tray 3 feed solenoid actuates.
Confirm solenoid operation by listening for the slight click of operation or watching for the rotation of thecorresponding shaft or roller when the power is turned off and on after the execution of the diagnosticroutine.
6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 284
D60 DRIVE MOTOR MAIN
The diagnostic code switches on the Main Motor.
MCU PWB
Main Motor
hc2m987F
FRONT
Chapter 3. Diagnostic Tools 285
To run D60 DRIVE MOTOR MAIN:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D60 DRIVE MOTOR MAIN displays.4. Press Enter to begin test.5. Verify that when you press Enter , the main motor switches on and rotates.
Confirm motor operation by listening for the sound of operation or by visual observation.6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the
test.7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 286
D63 MOTOR D CW (Duplex Motor Runs CW)
The diagnostic test switches on the Duplex Motor with clockwise rotation.
hc2m823F
Duplex Motor
DuplexUpper Roll
DuplexLower Roll
Pinch Roll
Rear RollAssembly
Duplex Sensor
Chapter 3. Diagnostic Tools 287
To run D63 MOTOR D CW:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D63 MOTOR D CW displays.4. Press Enter to begin test.5. Verify that when you press Enter , the duplex motor switches on and rotates.
Confirm motor operation by listening for the sound of operation or by visual observation.6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the
test.7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Chapter 3. Diagnostic Tools 288
D64 MOTOR D CCW (Duplex Motor Runs CCW)
The diagnostic test switches on the Duplex Motor in counter-clockwise rotation.
hc2m823F
Duplex Motor
DuplexUpper Roll
DuplexLower Roll
Pinch Roll
Rear RollAssembly
Duplex Sensor
Chapter 3. Diagnostic Tools 289
To run D64 MOTOR D CCW:
1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D64 MOTOR D CCW displays.4. Press Enter to begin test.5. Verify that when you press Enter , the duplex motor switches on and rotates in a counter-clockwise
direction (Open the cover and override the interlock to watch the motor rotate).6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the
test.7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
Confirm motor operation by listening for the sound of operation or by visual observation.
Chapter 3. Diagnostic Tools 290
D68 HCF MOTOR (HCF Transport Motor)
hc2m042F
2
1
Chapter 3. Diagnostic Tools 291
To run D68 HCF MOTOR:
1. Enter the DIAGNOSTICS MENU (see “Service Mode” on page 256).
2. Repeatedly press Item , stepping through the menu until D68 HCF MOTOR displays.3. Press Enter ; you should hear the HCF transport motor run.4. To view the transport roll turning, open the HCF rear cover and manually close the left and right hand
cover open switches.Press Cancel Print to stop the test; press Enter to restart the test.
Chapter 3. Diagnostic Tools 292
FACTORY ADJ MENUTable 58. Factory Adjustment Menu Items
Code Message Function
A01 Reg Top 1 Sets the top (lead) edge registration for paper fed from tray 1.
0-15 (16 steps) (Factory default 10)
0=Narrowest top edge registration gap
15=Widest top edge registration gap (approximately 0.5 mm per step)
(Go to “A01 Reg Top 1 (Leading Edge Registration, Tray 1)” on page 296.)
A03 Reg Top 2 Sets the top (lead) edge registration for paper fed from tray 2.
0-15 (16 steps) (Factory default 10)
0=Narrowest top edge registration gap
15=Widest top edge registration gap (approximately 0.5 mm per step)
(Go to “A03 Reg Top 2 (Leading Edge Registration, Tray 2)” on page 297.)
A05 Reg Top 3 Sets the top (lead) edge registration for paper fed from tray 3.
0-15 (16 steps) (Factory default 10)
0=Narrowest top edge registration gap
15=Widest top edge registration gap (approximately 0.5 mm per step)
(Go to “A05 Reg Top 3 (Leading Edge Registration, Tray 3)” on page 298.)
Chapter 3. Diagnostic Tools 293
Table 58. Factory Adjustment Menu Items (continued)
Code Message Function
A07 Reg Top A Sets the top (lead) edge registration for paper fed from auxiliary tray.
0-15 (16 steps) (Factory default 10)
0=Narrowest top edge registration gap
15=Widest top edge registration gap (approximately 0.54 mm per step)
(Go to “A07 Reg Top A (Leading Edge Registration, Aux. Tray)” on page 299.)
A09 Reg Left 1 Sets the left edge registration for paper fed from tray 1.
0-8 (9 steps) (Factory default 4)
0=Narrowest left edge registration gap
8=Widest left edge registration gap (approximately 0.5 mm per step)
(Go to “A09 Reg Left 1 (Left Edge Registration, Tray 1)” on page 300.)
A11 Reg Left 2 Sets the left edge registration for paper fed from tray 2.
0-8 (9 steps) (Factory default 4)
0=Narrowest left edge registration gap
8=Widest left edge registration gap (approximately 0.5 mm per step)
(Go to “A11 Reg Left 2 (Left Edge Registration, Tray 2)” on page 301.)
Chapter 3. Diagnostic Tools 294
Table 58. Factory Adjustment Menu Items (continued)
Code Message Function
A13 Reg Left 3 Sets the left edge registration for paper fed from tray 3.
0-8 (9 steps) (Factory default 4)
0=Narrowest left edge registration gap
8=Widest left edge registration gap (approximately 0.5 mm per step)
(Go to “A13 Reg Left 3 (Left Edge Registration, Tray 3)” on page 302.)
A15 Reg Left A Sets the left edge registration for paper fed from auxiliary tray.
0-8 (9 steps) (Factory default 4)
0=Narrowest left edge registration gap
8=Widest left edge registration gap (approximately 0.5 mm per step)
(Go to “A15 Reg Left A (Left Edge Registration, Aux. Tray)” on page 303.)
A21 Fuser Temp Sets the rated fuser temperature.Note: This setting is intended for manufacturing and engineering use. Keep atfactory default.
0-15 (16 steps) (Factory default 5)
0=Lowest rated temperature.
15=Highest rated temperature. (approximately 4.0°C per step)
(Go to “A21 Fuser Temp (Adjustment)” on page 304.)
Chapter 3. Diagnostic Tools 295
A01 Reg Top 1 (Leading Edge Registration, Tray 1)
This factory adjustment sets the top (lead) edge registration for paper fed from Tray 1.
Use A01 REG TOP 1 to verify that there is a registration problem in Tray 1. (See page 257.)
To perform the adjustment:
1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A01 REG TOP 1 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 296
A03 Reg Top 2 (Leading Edge Registration, Tray 2)
This factory adjustment sets the top (lead) edge registration for paper fed from Tray 2.
Use a real job printed from Tray 2 to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A03 REG TOP 2 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 297
A05 Reg Top 3 (Leading Edge Registration, Tray 3)
This factory adjustment sets the top (lead) edge registration for paper fed from Tray 3.
Use a real job printed from Tray 3 to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A05 REG TOP 3 displays.4. PressValue to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 298
A07 Reg Top A (Leading Edge Registration, Aux. Tray)
This factory adjustment sets the top (lead) edge registration for paper fed from the AUX tray.
Use a real job printed from the AUX tray to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A07 REG TOP A displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 299
A09 Reg Left 1 (Left Edge Registration, Tray 1)
This factory adjustment sets the left edge registration for paper fed from Tray 1.
Use D01 TEST PRINT to verify that there is a registration problem. (See page 257.)
To perform the adjustment:
1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A09 REG LEFT 1 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 300
A11 Reg Left 2 (Left Edge Registration, Tray 2)
This factory adjustment sets the left edge registration for paper fed from Tray 2.
Use a real job printed from Tray 2 to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A11 REG LEFT 2 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 301
A13 Reg Left 3 (Left Edge Registration, Tray 3)
This factory adjustment sets the left edge registration for paper fed from Tray 3.
Use a real job printed from Tray 3 to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A13 REG LEFT 3 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 302
A15 Reg Left A (Left Edge Registration, Aux. Tray)
This factory adjustment sets the left edge registration for paper fed from the auxiliary tray.
Use a real job printed from the AUX tray to verify that there is a registration problem.
To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A15 REG LEFT A displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 303
A21 Fuser Temp (Adjustment)
This factory adjustment sets the fuser temperature.
Use D13 FUSER TEMP (Current Setting) to show the current setting and actual reading. (See page 259.)
To perform the adjustment:
1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).
2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A21 FUSER TEMP displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory
adjustment value (See Table 57 on page 260 and Table 58 on page 293).
5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.
6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.
Chapter 3. Diagnostic Tools 304
S/N = 00-00000 (Serial Number)
The following procedure enters the printer serial number into the printer MCU NVRAM (see Figure 5 onpage 363 for the location of the printer serial number). This allows the correct serial number to print on theconfiguration page. This value is set at the factory. Use this procedure only if you have installed a new MCUPWB.
To run S/N = 00-00000, perform the following:
1. Enter the FACTORY ADJ MENU (see “FACTORY ADJ MENU” on page 293).
2. Repeatedly press Shift +Item to wrap to the end of the menu item list, S/N = 00-00000 will be displayed.You are now ready to change the left most position of the serial number.
3. Press Value to increase the number, or press Shift Value to decrease the number in that position.Each position has a numerical range from 0–9, and an alpha range from A–F.
4. Press Enter to accept the value and move to the next position.5. Repeat for each position. After the last position is enterd, press Enter again until an asterisk appears at
the right of the serial number. This indicates that the updated serial number information has been stored inthe printer NVRAM.
6. Switch printer power off, and then on again.
Chapter 3. Diagnostic Tools 305
Menu Items Not DescribedThe following menu items are not described. If necessary, technical support will guide you through them.v D81 HVPS CHG DCv D83 HVPS DEV BIAS DCv A22 PRF=Enable/Disablev A22 SFS=Enable/Disablev A23 TNS=Enable/Disablev A26 OCT=Enable/Disablev A27 FUS=Enable/Disable
Chapter 3. Diagnostic Tools 306
Chapter 4. Circuit DiagramsMaster Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310Wiring and Signal Description between Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
MCU ⇔ LVPS ⇔ INTERLOCK SWITCH and FANs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .311Signal names for the MCU ⇔ LVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
MCU ⇔ FUSER ASSEMBLY ⇔ LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313Signal names for the MCU ⇔ Fuser Assembly path . . . . . . . . . . . . . . . . . . . . . . . . . . .314Pin numbers and voltage levels for the MCU ⇔ Fuser Assembly path . . . . . . . . . . . . . . . . . .314
MCU ⇔ ROS and CRU SENSOR ASSEMBLY (CRU SWITCH and LD SWITCH) . . . . . . . . . . . . .315Signal names for the MCU ⇔ ROS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316Pin numbers and voltage levels for the MCU ⇔ ROS path . . . . . . . . . . . . . . . . . . . . . . . .317Selection of the print resolution with SP11 and SP12 . . . . . . . . . . . . . . . . . . . . . . . . . . .318
MCU ⇔ HVPS ⇔ EP CARTRIDGE (BCR and MAG. ROLL), BTR, and DETACK SAW . . . . . . . . . .319Signal names for the MCU ⇔ HVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320Pin numbers and voltage levels for the MCU ⇔ HVPS path . . . . . . . . . . . . . . . . . . . . . . .321
MCU ⇔ REG. CLUTCH, REG. SENSOR, PICK UP SOLENOID, and AUX TRAY NO-PAPER SENSOR. .322Signal names for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper
Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323Pin numbers and voltage levels for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux
Tray No-Paper Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324MCU ⇔ FEEDER1 PWB ⇔ FEED SOLENOID, CST NO-PAPER SENSOR, and ELECTROMAGNETIC
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325Signal names for the MCU ⇔ FEEDER1 PWB path . . . . . . . . . . . . . . . . . . . . . . . . . . .326Pin numbers and voltage levels for the MCU ⇔ FEEDER1 PWB path . . . . . . . . . . . . . . . . . .328
MCU ⇔ MAIN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329Signal names for the MCU ⇔ Main Motor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330Pin numbers and voltage levels for the MCU ⇔ Main Motor path. . . . . . . . . . . . . . . . . . . . .330
MCU ⇔ TONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331
© Copyright IBM Corp. 1998 307
Signal names for the MCU ⇔ Toner Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331Pin numbers and voltage levels for the MCU ⇔ Toner Sensor path. . . . . . . . . . . . . . . . . . . .331
MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH or MCU ⇔ FUSER COVER SWITCH . . . . . .332Signal names for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH path . . . . . . . . . . .333Pin numbers and voltage level for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH path . .333Signal names for the MCU ⇔ FUSER COVER SWITCH path . . . . . . . . . . . . . . . . . . . . . .333Pin numbers and voltage level for the MCU ⇔ FUSER COVER SWITCH path. . . . . . . . . . . . . .333
CONTROLLER ⇔ CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334Signal names for the Controller ⇔ Control Panel path . . . . . . . . . . . . . . . . . . . . . . . . . .335Pin numbers and voltage levels for the CONTROLLER ⇔ CONTROL PANEL path . . . . . . . . . . .336
CONTROLLER ⇔ MCU and LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337Signal names for the Controller ⇔ MCU path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338Pin numbers and voltage levels for the Controller ⇔ MCU path . . . . . . . . . . . . . . . . . . . . .338Signals between the Controller and the MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
MCU ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feed Solenoid, No Paper Sensor, andElectromagnetic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342Signal names for the Feeder PWB ⇔ Feeder PWB path . . . . . . . . . . . . . . . . . . . . . . . . .344Pin numbers and voltage levels for the Feeder PWB (Feeder1) ⇔ Feeder PWB (Feeder2) path . . . . .345Pin numbers and voltage levels for the Feeder PWB (Feeder2) ⇔ Feeder PWB (Feeder3) path . . . . .346Detection of the Feeder configuration through the FEEDER CHECK signal. . . . . . . . . . . . . . . .347
MCU ⇔ Duplex I/F PWB⇔ Duplex PWB and Fuser Cover Switch Duplex PWB ⇔ Dup Stack Sensor,Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor . . . . .349Signal names for the Duplex I/F PWB ⇔ Duplex PWB path . . . . . . . . . . . . . . . . . . . . . . .350Pin numbers and voltage levels for the Duplex I/F PWB ⇔ Duplex PWB path . . . . . . . . . . . . . .351Signal names for the Duplex PWB ⇔ Offset Motor path . . . . . . . . . . . . . . . . . . . . . . . . .351Pin numbers and voltage levels for the Duplex PWB ⇔ Offset Motor path . . . . . . . . . . . . . . . .352
HCF LVPS⇔ Components, HCF LVPS ⇔ FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . .353Signal names for the HCF LVPS ⇔ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354Signal names for the HCF LVPS ⇔ FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Chapter 4. Circuit Diagrams 308
Pin numbers and voltage levels for the HCF LVPS ⇔ Components. . . . . . . . . . . . . . . . . . . .357
Chapter 4. Circuit Diagrams 309
Master Wiring Diagram
M M
M
CONTROLPANEL
CONTROLLER
LVPS
DUPLEX INTERFACE PWB
FUSER
COVERSWITCH
COVERSWITCH
DUPLEX PWB
MCU
HVPS
EP Cartridge
ROS
LD SOS MOT
OCTMOT
DUPMOT
MAIN MOT
CRU SNS
TONERSNS
REGCLH
REG SNS
NOP SNSAUX
AUXFEEDSOL
MAIN FAN
ACINLET
INTERLOCKSWITCH
TEST PRINT
FULLSNS
/DUPCOVER
SWITCH1
/DUPCOVER
SWITCH2DUPSNS
P/J197
P/J195
DB CR DTS TR
P/J186
P/J196
P/J192
P/J193
P/J198
P/J184 P/J187
P183
P/J151
P/J15
P/J112
P/J113
P/J114
P/J12
P/J16
P/J17
P/J22
P/J13
P/J18
P/J180
P/J142
P/J942
J131 CN1
P/J14
P/J31
P/J19
P/J20
P207
P207
P/J122 P/J
123
P/J126
P/J127 P/J121
P/J11P/J21
P23
P/J124
P/J132
P/J134
P/J171
P/J145
P/J144
P/J
922
P/J
222
P/J
131
P/J
131
P/J
937
P/J
135
P/J
143
P/J
137
P/J
935
P/J
943
P182
EXITSENSOR
FULL STACKSENSOR
HEATER ROD
TEMPERATURESENSOR
THERMOSTAT THERMALFUSE
MAIN SWITCH
J130
FEEDER1P/J203
P202
TURNCLH
NOPAPER
FEEDSOL
P/J
204
P/J
904
P/J
205
P/J
206
P201
FEEDER2P/J203
P202
TURNCLH
NOPAPER
FEEDSOL
P/J
204
P/J
904
P/J
205
P/J
206
P201
FEEDER3P/J203
TURNCLH
NOPAPER
FEEDSOL
P/J
204
P/J
904
P/J
205
P/J
206
P201
P/J
221
P/J190
HC2M994F
OPTIONAL
OPTIONAL
Chapter 4. Circuit Diagrams 310
Wiring and Signal Description between Components
MCU ⇔ LVPS ⇔ INTERLOCK SWITCH and FANs
MCU
LVPS
INTERLOCKSW
INTERLOCKSW
MAIN FANFG
FG
AC
L N
24VDC
24VDC
P/J123
P/J11
P/J21
P/J121
P/J122 P124
2
1
1
2
3
4
5
6
6
5
4
3
2
1
RTN
5VDC
SG
/HEAT(TTL)
FAN ALARM(TTL)
/FAN FAST ON(L)24VDC
FAN
ON
FAN
ALA
RM
(TT
L)
RT
N
FANCONTROL
HEATERCONTROL
24VDCSUPPLY
5VDCSUPPLY
hc2m995F
1 2 3
1
1 2 3
Chapter 4. Circuit Diagrams 311
Signal names for the MCU ⇔ LVPS pathSignal Name Description
/HEAT (TTL) Fuser control signal to switch AC power to the Heater Rod on and off.
Low: On, High: Off
FAN ALARM (TTL) Fan monitor signal. Goes High when the rotation of the Main Fan is abnormal.
/FAN FAST ON(L) 24V Fan speed switching signal that switches the speed of rotation of the Main Fan between Highand Low.
Low: High speed, High: Low speed
Chapter 4. Circuit Diagrams 312
MCU ⇔ FUSER ASSEMBLY ⇔ LVPS
FUSER
FG FG
MCU
LVPS
FGAC
L
N
HEATER
CONTROL
FULL STACK SENSOR
EXIT SENSOR
HEAT ROLL
P/J145 P/J942 P/J142 P/J14
P/J124P146-1
FUSER COVEROPEN SWITCH
J146-1
5VDC
P/J143 P/J943
P/J144
1
2
3
1
2
3
1
2
2
1
TEMPERATURESENSOR
HEATER ROD
THERMOSTAT THERMAL FUSE
PRESSURE ROLL
ELIMINATOR
AC L AC L
AC N AC N
/FULL(TTL)
SG
P.UP
TEMP.
SG
/EXIT(TTL)
SG
P.UP
A1
A2
A3
A4
B1
B2
B3
B4
4
3
2
1
8
7
6
5
4
3
2
1
1
2
3
A4
A3
A2
A1
B1
B2
B3
B4
hc2m996F
Chapter 4. Circuit Diagrams 313
Signal names for the MCU ⇔ Fuser Assembly pathSignal Name Description
/EXIT (TTL) Signal from the Exit Sensor. This signal is Low when the Exit Sensor is activated.
TEMP. Temperature monitor signal (analog signal) from the Temperature Sensor Assembly (Thermistor) thatindicates the temperature of the Heat Roll surface.
/FULL (TTL) Signal from the Full Stack Sensor. This signal is Low when the Full Stack Sensor is activated by thestack of printed sheets higher than the predetermined height.
Pin numbers and voltage levels for the MCU ⇔ Fuser Assembly path
P14 P142 P942 Signal Name Signal Direction TriggerHighLevel
LowLevel Note
3 B2 B2 P144-1 /EXIT (TTL) MCU⇐Fuser Level TTL TTL
5 A4 A1 P943-1 P143-2 TEMP. MCU⇐Fuser * * * Analog
8 A1 A4 P145-1 /FULL (TTL) MCU⇐Fuser Level TTL TTL
Chapter 4. Circuit Diagrams 314
MCU ⇔ ROS and CRU SENSOR ASSEMBLY (CRUSWITCH and LD SWITCH)
MCU
ROS
MOT
1
2
3
4
5
6
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1 2 3 4
4 3 2 1
24VDC
RTN
/RMOT ON(TTL)
/SP11(TTL)
/SP12(TTL)
5VDC
/SOS(TTL)
SG
5VDC-LD
SG
VL1
VL2
MO
5VDC
/P.DATA(TTL)
5VD
C
5VD
C-L
D
SG
NO
CR
U
1
2
3
1
2
3
4
5
6
7
CRU SENSOR
SOS
LD
P/J114
P/J113
P/J112
P/J125VDC
LDSWITCH
CRUSWITCH
P/J17
P/J171
hc2m997F
Chapter 4. Circuit Diagrams 315
Signal names for the MCU ⇔ ROS pathSignal Name Description
/RMOT ON (TTL) Scanner Motor Control signal that switches the Scanner Motor on and off.
Low: On, High: Off
/SP11 (TTL) Print resolution selection signal that selects a ratio of frequency division of the clock signal.
/SP12 (TTL) Print resolution selection signal that selects a ratio of frequency division of the clock signal.
/SOS (TTL) Synchronization signal generated by the SOS PWBA that indicates the start of each scan.
5VDC-LD Laser Diode drive power causing the Laser Diode to emit laser light. This 5VDC supply to the LaserDiode is interrupted by the deactivation of the LD Switch in the CRU Sensor assembly.
VL1 Laser power control signal that determines (or adjusts) the current flowing through the Laser Diode(analog signal).
VL2 Laser power control signal that dete.rmines (or adjusts) the current flowing through the Laser Diode(analog signal).
MO Laser power monitor signal that feeds back the power of the laser light emitted by the Laser Diode(analog signal).
/P. DATA (TTL) Print image data (Low = Black dot, High = White dot).
Chapter 4. Circuit Diagrams 316
Pin numbers and voltage levels for the MCU ⇔ ROS path
P11P112, P113, andP114 Signal Name
Signal Direction
M: MCU, L: LD
S: SOS
SM: Scanner Motor
R: ROS PWB TriggerHighLevel
LowLevel Note
13 P114-3 /RMOT ON (TTL) MCU⇒Scanner Motor Level TTL TTL
12 P114-5 /SP11 (TTL) MCU⇒ROS PWB Level TTL TTL
11 P114-6 /SP12 (TTL) MCU⇒ROS PWB Level TTL TTL
9 P113-2 /SOS (TTL) MCU⇐SOS Level TTL TTL
7 P112-1 5VDC-LD MCU⇒L - 5VDC 0V
5 P112-3 VL1 MCU⇒L - * * 0 ∼ 3.5 V
4 P112-4 VL2 MCU⇒L - * * 0 ∼ 3.5 V
3 P112-5 MO MCU⇐L - * * 0.7 ∼ 1.4 V
1 P112-7 /P. DATA (TTL) MCU⇒L Level TTL TTL
Chapter 4. Circuit Diagrams 317
Selection of the print resolution with SP11 and SP12Resolution SP12 SP11
600/300 dpi ROS Assembly
600 dpi * H H
300 dpi H L
600/360 dpi ROS Assembly
600 dpi * L L
360 dpi H L
600/400 dpi ROS Assembly
600 dpi * L H
400 dpi L L
600/480 dpi ROS Assembly
600 dpi * L H
480 dpi H L
480/400 dpi ROS Assembly
480 dpi * H H
400 dpi L L
800/600 dpi ROS Assembly
800 dpi * L L
600 dpi L H
* Factory setting
Chapter 4. Circuit Diagrams 318
MCU ⇔ HVPS ⇔ EP CARTRIDGE (BCR and MAG.ROLL), BTR, and DETACK SAW
DRUM
DTS
TR
HVPS
MCU
DB
BCR
BTR
MAG.ROLLMAG.ROLL CR
24V
DC
RT
N
DB
-AC
/DB
-DC
ON
(L)
24V
DC
/CR
-DC
ON
(L)
24V
DC
/CR
-AC
ON
(L)
24V
DC
/DT
SO
N(L
)24
VD
C
/TR
(+)
ON
(L)
24V
DC
/TR
ON
(L)
24V
DC
TR
MO
-I
TR
MO
-V
BT
R-D
/A
DT
S-D
/A
CRU GUIDEASSEMBLY L
TRANS.CHUTEASSEMBLY L
DETACK SAW
CRU GUIDEASSEMBLY R
EP CARTRIDGE
P/J151
P/J151 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3
9 8 7 6 5 4 3 2 11 3 1 2 11 1 0
hc2m998F
Chapter 4. Circuit Diagrams 319
Signal names for the MCU ⇔ HVPS pathSignal Name Description
DB-AC (TTL) Constant-frequency pulse signal that provides the source of oscillation for generating the ACcomponent of the DB (Development Bias) in the HVPS.
/DB-DC ON(L) 24VDC Control signal to switch the DC component of the DB on and off.
/CR-DC ON(L) 24VDC Control signal to switch the DC component of the CR on and off.
/CR-AC ON(L) 24VDC Control signal to switch the AC component of the CR on and off.
/DTS ON(L) 24VDC Control signal to switch the DTS on and off.
/TR(+) ON(L) 24VDC Control signal to switch the TR voltage between TR(+) and TR(-)
Low: TR(+), High: TR(-).
TR ON(L) 24VDC Control signal to switch the TR voltage on and off.
TR(+) or TR(-) is output according to the selection by the /TR(+) ON(L) signal.
TRMO-I Monitor signal of the TR(+) voltage when a constant-current output is selected by the ATDVC* (0∼ 5 VDC).
TRMO-V Monitor signal of the TR(+) current when a constant-voltage output is selected by the ATDVC*(0.4 ∼ 4.7 VDC).
BTR-D/A Control signal to select the TR(+) voltage as determined by the ATDVC.
DTS-D/A Control signal to select the DTS voltage as determined by the ATDVC.
* Active Transfer and Detack Voltage Control
Chapter 4. Circuit Diagrams 320
Pin numbers and voltage levels for the MCU ⇔ HVPS path
P15 P151 Signal Name Signal Direction TriggerHighLevel
LowLevel Note
3 11 DB-AC MCU⇒HVPS Level TTL TTL
4 10 /DB-DC ON(L) 24VDC MCU⇒HVPS Level 24V 0V
5 9 /CR-DC ON(L) 24VDC MCU⇒HVPS Level 24V 0V
6 8 /CR-AC ON(L) 24VDC MCU⇒HVPS Level 24V 0V
7 7 /DTS ON(L) 24VDC MCU⇒HVPS Level 24V 0V
8 6 /TR(+) ON(L) 24VDC MCU⇒HVPS Level 24V 0V
9 5 TR ON(L) 24VDC MCU⇒HVPS Level 24V 0V
10 4 TRMO-I MCU⇐HVPS Level * * Analog
11 3 TRMO-V MCU⇐HVPS Level * * Analog
12 2 BTR-D/A MCU⇒HVPS Level * * Analog
13 1 DTS-D/A MCU⇒HVPS Level * * Analog
Chapter 4. Circuit Diagrams 321
MCU ⇔ REG. CLUTCH, REG. SENSOR, PICK UPSOLENOID, and AUX TRAY NO-PAPER SENSOR
3
2
1
3
2
1
MCU
REGISTRATIONCLUTCHASSEMBLY
REGISTRATIONSENSOR
FEED SOLENOID(PICK UP SOLENOID)
AUX TRAYNO PAPERSENSOR
P.UP
SG
/REGIN(TTL)
PICK UP ON(L) 24VDC
24VDC
P.UP
SG
/NO PAPER0(TTL)
24VDC
REG. ON(L) 24VDC
P/J131
P/J13
P/J132
P/J935P/J135
P/J137P/J937P/J134
TRANSPORT CHUTE ASSEMBLY
1
2
3
4
5
6
7
8
9
10
4
3
2
1
3
2
1
2
1
3
2
1
1
2
3
1
2
hc2m999F
Chapter 4. Circuit Diagrams 322
Signal names for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux TrayNo-Paper Sensor pathSignal Name Description
REG. ON(L) 24VDC Registration Clutch control signal. The Registration Clutch is activated when this signal isLow, and deactivated when High.
/REG. IN (TTL) Signal from the Registration Sensor. This signal is Low when the Registration Sensor isactivated.
/NO PAPER0 (TTL) Signal from the Aux Tray No-Paper Sensor (Front Tray). This signal is Low when the SINo-Paper Sensor is activated.
PICK UP ON(L) 24VDC Pick Up Solenoid control signal. The Pick Up Solenoid is activated when this signal is Low,and deactivated when High.
Chapter 4. Circuit Diagrams 323
Pin numbers and voltage levels for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick UpSolenoid, and Aux Tray No-Paper Sensor path
P13 Signal Name
Signal Direction
M: MCU,
RC: Reg. Clutch
RS: Reg. Sensor
AT: Aux Tray No-Paper Sen.
FS: Feed Solenoid TriggerHighLevel
LowLevel
2 P131-1 REG. ON(L) 24VDC M⇒RC Level TTL TTL
5 P132-1 /REG. IN (TTL) M⇐RS Level 24V 0V
8 P137-1 /NO PAPER0 (TTL) M⇐AT Level 24V 0V
10 P935-1 PICK UP ON(L) 24VDC M⇒FS Level 24V 0V
Chapter 4. Circuit Diagrams 324
MCU ⇔ FEEDER1 PWB ⇔ FEED SOLENOID, CSTNO-PAPER SENSOR, and ELECTROMAGNETICCLUTCH
MCU
FEEDER1
FEED SOLENOIDCST NO PAPERSENSOR
ELECTROMAGNETICCLUTCH
A
B
C
CD
XZ
BE
AF
F
E
D
YW
24VDC
5VDC
4 3 2 1
1 2 3 4 5 6 7 8 9
3 2 1 1 2
2 1
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
PSIZE3 (TTL)
PSIZE1 (TTL)
/FEED3 ON(L) 24VDC
/FEED1 ON(L) 24VDC
/SIZE 3BIT(TTL)
/SIZE 1BIT(TTL)
/NO PAPER3 (TTL)
/NO PAPER1 (TTL)
FEEDER CHECK
5VDC
24VDC
RTN
SG
OPTION
/NO PAPER2 (TTL)
OPTION
/SIZE 2BIT(TTL)
/SIZE 4BIT(TTL)
/FEED2 ON(L) 24VDC
TURN (TTL)
PSIZE2 (TTL)
N.C.
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
N.C.
/TU
RN
ON
(L)
24V
DC
24V
DC
P.U
P
SG
/NO
PA
PE
R1
(TT
L)
24V
DC
/FE
ED
1O
N(L
)24
VD
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
24VDC
P/J203
P/J204
P/J904
P/J205
P/J206
P/J201
P/J202
P207P/J20
wXYZ
5VDC5VDC
SW1
PAPERSIZE
SWITCH
SIZESENSE
SW2
SW3
SW4
N.C.
hc2m800F
Chapter 4. Circuit Diagrams 325
Signal names for the MCU ⇔ FEEDER1 PWB pathSignal Name Description
PSIZE3 (TTL) Selects the Paper Size Switches of Feeder 3. When this signal is High, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.
PSIZE1 (TTL) Selects the Paper Size Switches of Feeder 1. When this signal is High, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 1 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.
/FEED3 ON(L) 24VDC Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) is activatedwhen this signal is Low, and deactivated when High.
/FEED1 ON(L) 24VDC Feed Solenoid 1 control signal. The Feed Solenoid 1 (Feed Solenoid of the Feeder 1) is activatedwhen this signal is Low, and deactivated when High.
/SIZE 3BIT (TTL) Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 3 is activated.
/SIZE 1BIT (TTL) Signal from the Paper Size Switch 1 of the Feeder selected with PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 1 is activated.
/NO PAPER3 (TTL) Signal from the No Paper Sensor 3 (No Paper Sensor of the Feeder 3). This signal is Low whenthe No Paper Sensor 3 is activated.
/NO PAPER1 (TTL) Signal from the No Paper Sensor 1 (No Paper Sensor of the Feeder 1). This signal is Low whenthe No Paper Sensor 1 is activated.
FEEDER CHECK Signal that indicates the Feeder Configuration.
OPTION Reserved for option.
/NO PAPER2 (TTL) Signal from the No Paper Sensor 2 (No Paper Sensor of the Feeder 2). This signal is Low whenthe No Paper Sensor 2 is activated.
/SIZE 2BIT (TTL) Signal from the Paper Size Switch 2 of the Feeder selected with PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 2 is activated.
Chapter 4. Circuit Diagrams 326
Signal Name Description
/SIZE 4BIT (TTL) Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 4 is activated.
/FEED2 ON(L) 24VDC Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) is activatedwhen this signal is Low, and deactivated when High.
TURN (TTL) Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutchis activated when this signal is Low, and deactivated when High.
PSIZE2 (TTL) Selects the Paper Size Switches of Feeder 2. When this signal is High, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.
Chapter 4. Circuit Diagrams 327
Pin numbers and voltage levels for the MCU ⇔ FEEDER1 PWB path
P20 P201 Signal Name
Signal Direction
M: MCU, F: Feeder1 TriggerHighLevel
LowLevel Note
A1 A11 PSIZE3 (TTL) M⇒F Level TTL TTL
A2 A10 PSIZE1 (TTL) M⇒F Level TTL 0V
A3 A9 /FEED3 ON(L) 24VDC M⇒F Level 24V 0V
A4 A8 /FEED1 ON(L) 24VDC M⇒F Level 24V 0V
A5 A7 /SIZE 3BIT (TTL) M⇐F Level TTL TTL
A6 A6 /SIZE 1BIT (TTL) M⇐F Level TTL TTL
A7 A5 /NO PAPER3 (TTL) M⇐F Level TTL TTL
A8 A4 /NO PAPER1 (TTL) M⇐F Level TTL TTL
A9 A3 FEEDER CHECK M⇐F Level * * Analog
B3 B10 OPTION M⇐F Level
B4 B9 /NO PAPER2 (TTL) M⇐F Level TTL TTL
B6 B7 /SIZE 2BIT (TTL) M⇐F Level TTL TTL
B7 B6 /SIZE 4BIT (TTL) M⇐F Level TTL TTL
B8 B5 /FEED2 ON(L) 24VDC M⇒F Level 24V 0V
B9 B4 TURN (TTL) M⇒F Level TTL TTL
B10 B3 PSIZE2 (TTL) M⇒F Level TTL TTL
Chapter 4. Circuit Diagrams 328
MCU ⇔ MAIN MOTOR
M
MCU
MAIN MOTORP/J16
24VDC
RTN
/MOT REV (TTL)
MOT ALM (TTL)
/MAIN MOT(TTL)
1
2
3
4
5
hc2m801F
Chapter 4. Circuit Diagrams 329
Signal names for the MCU ⇔ Main Motor pathSignal Name Description
/MOT REV (TTL) Control signal to switch the direction of the rotation of the Main Motor between Normal andReverse.
Low: Reverse direction, High: Normal direction
MOT ALARM (TTL) Main Motor monitor signal. Goes Low when the rotation of the Main Motor is abnormal.
/MAIN MOT (TTL) Main Motor Control Signal to switch the Main Motor on and off.
Pin numbers and voltage levels for the MCU ⇔ Main Motor pathP16 Signal Name Signal Direction Trigger High Level Low Level
3 /MOT REV (TTL) MCU⇒Main Motor Level TTL TTL
4 MOT ALARM (TTL) MCU⇐Main Motor Level TTL TTL
5 /MAIN MOT (TTL) MCU⇒Main Motor Level TTL TTL
Chapter 4. Circuit Diagrams 330
MCU ⇔ TONER SENSOR
Signal names for the MCU ⇔ Toner Sensor pathSignal Name Description
/NO TONER (TTL) Signal from the Toner Sensor. Goes Low when toner is low in the EP Cartridge.
Pin numbers and voltage levels for the MCU ⇔ Toner Sensor path
P22 P222 P922 P221 Signal Name Signal Direction TriggerHighLevel
LowLevel
4 1 4 4 /NO TONER (TTL) MCU⇐Toner Sensor Level TTL TTL
TONER SENSOR
MCU
24VDC
N.C.
SG
/NO TONER (TTL)
P/J22P/J221P/J222
P/J922
1
2
3
4
1
2
3
4
4
3
2
1
1
2
3
4
hc2m802F
Chapter 4. Circuit Diagrams 331
MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCHor MCU ⇔ FUSER COVER SWITCH
MCUDUPLEX I/F PWB
1
2
1
2
2
1
2
1
2
1
2
1
COVERSWITCHCOVERSWITCH
COVERSWITCHCOVERSWITCH
91 2 10 3 11 4 12 5 13 6 14 7 15 8
P/J190
P/J190
P/J180
P/J18
J182
SG
/FCOVER OPEN (TTL)
/FCOVER OPEN (TTL)
OR
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1 hc2m803F
Chapter 4. Circuit Diagrams 332
Signal names for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH pathSignal Name Description
/FCOVER OPEN (TTL) Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch isdeactivated (the Fuser Cover is open).
Pin numbers and voltage level for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVERSWITCH path
P18 P180 P190 Signal Name Signal Direction TriggerHighLevel
9 1 2 /FCOVER OPEN (TTL) MCU⇐Fuser Cover Switch Level TTL
Signal names for the MCU ⇔ FUSER COVER SWITCH pathSignal Name Description
/FCOVER OPEN Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch isdeactivated (the Fuser Cover is open).
Pin numbers and voltage level for the MCU ⇔ FUSER COVER SWITCH path
P18 P190 Signal Name Signal Direction TriggerHighLevel
8 1 /FCOVER OPEN (TTL) MCU⇐Fuser Cover Switch Level TTL
Chapter 4. Circuit Diagrams 333
CONTROLLER ⇔ CONTROL PANEL
CONTROLLER
CONTROL PANEL
P/J411
P412
P/J421/LED 4 (TTL)
/LED 3 (TTL)
/LED 2 (TTL)
/LED 1 (TTL)
/KEY 1 (TTL)
/KEY 2 (TTL)
/KEY 3 (TTL)
/KEY 4 (TTL)
/KEY 5 (TTL)
/KEY 6 (TTL)
/KEY 7 (TTL)
/KEY 8 (TTL)
DB7 (TTL)
DB6 (TTL)
DB5 (TTL)
DB4 (TTL)
E (TTL)
RS (TTL)
5VDC
SG
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
hc2m804F
Chapter 4. Circuit Diagrams 334
Signal names for the Controller ⇔ Control Panel pathSignal Name Description
/LED1 (TTL) ∼ /LED4 (TTL) LED switching signals. When these signals goes Low, the corresponding LEDsilluminate.
/KEY1 (TTL) ∼ /KEY8 (TTL) Key signals. When a key is pressed, the corresponding KEY signal goes Low.
DB4 ∼ DB7 (TTL) 4-bit data signals.
E (TTL) LCD enabling signal.
Low: Disable, High: Enable
16X2 TN LCD MODULE
To Controller +5v+5vP421- 2
P421- 1
P421- 4P421- 3P421- 8P421- 7P421- 6P421- 5P421- 9P421-10P421-11P421-12P421-13P421-14P421-15P421-16
P421-17P421-18P421-19P421-20
SG
10
K
ERSDB7DB6DB5DB4KEY8KEY7KEY6KEY5KEY4KEY3KEY2KEY1
SW
1
SW
2
SW
3
SW
4
SW
5
SW
6
SW
7
SW
8
LE
D1
LE
D2
LE
D3
LE
D4
LED1LED2LED3LED4
15
0
¶
15
0
¶
15
0
¶
15
0
¶
DB
3D
B2
DB
1D
B0
R/W
VS
SV
0V
DD
+5V
47ALM
Ê0.1CER
Ê +
hc2m941F
Online
Menu
AttentionBuffer
CancelPrint
Item
Shift
Continue Enter*
Value +
-
Chapter 4. Circuit Diagrams 335
Signal Name Description
RS (TTL) Register selecting signal which selects the command registers or the data registers.
Low: Command registers, High: Data registers
Pin numbers and voltage levels for the CONTROLLER ⇔ CONTROL PANEL path
P411 P421 Signal Name
Signal Direction
C: Controller
CP: Control Panel TriggerHighLevel
1∼4 20∼17 /LED4 (TTL) ∼ /LED1 (TTL) C⇒CP Level TTL
5∼12 16∼9 /KEY1 (TTL) ∼ /KEY8 (TTL) C⇐CP Level TTL
13∼16 8∼5 DB7(TTL) ∼ DB4 (TTL) C⇒CP Level TTL
17 4 E (TTL) C⇒CP Level TTL
18 3 RS (TTL) C⇒CP Level TTL
Chapter 4. Circuit Diagrams 336
CONTROLLER ⇔ MCU and LVPS
CONTROLLER
LVPS
MCU
5VDC
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
1
2
/TPRINT (TTL)
SG
1
2
5VDC
SG
/TPRINT
/PRFD
/CCLK
/VDO
+5V
/CBSY
/STA
/TOP
/PPRDY
SG
SG
SG
SG
/CMD
/CPRDY
/START
/PCLK
/SBSY
/RDY
/BD
P411
P23
P/J31
P/J412
P/J126
1 2
hc2m805F
Chapter 4. Circuit Diagrams 337
Signal names for the Controller ⇔ MCU pathSignal Name Description
/TPRINT (TTL) Test print. Printing test starts when this signal goes Low.
Pin numbers and voltage levels for the Controller ⇔ MCU pathP/J31 Signal Name Signal Direction Trigger High Level Low Level
A1 /TPRINT MCU⇐Controller Level TTL TTL
Chapter 4. Circuit Diagrams 338
Signals between the Controller and the MCU
The table below lists the signals that are used between the Controller and the MCU.
PIN SIGNAL DIRECTION DESCTIPTION
A9 /PPRDY MCU⇒Controller Printer Power Ready: Goes Low when the printer is powered onand completes initialization. The printer is in ON-LINE mode.
A8 /TOP MCU⇒Controller Top of Paper: Vertical synchronization signal.
A7 /STA MCU⇒Controller Status: The MCU sends a Status serially in synchronism with/PCLK (/CCLK when the Controller requests the MCU to use it).
A6 /CBSY MCU⇐Controller Command Busy: The Controller holds this signal Low whilesending a Command.
A4 /VDO MCU⇐Controller Video: The Controller sends print data to the MCU, synchronizingthe beginning of each page and each line (raster line) of the printdata with /TOP and /BD, respectively. The transmission ratedepends on the print resolution.v 300dpi: 4.41769 MHz/480dpi: 11.30930 MHzv 360dpi: 6.36148 MHz/600dpi: 17.67078 MHzv 400dpi: 7.85368 MHz/800dpi: 31.41472 MHz
A3 /CCLK MCU⇐Controller Controller Clock: Clock signal that is supplied by the Controller andused for synchronous transmission of a Command by theController. The MCU uses this clock signal for transmission of aStatus when requested to use it by the Controller.
A2 /PRFD MCU⇐Controller Prefeed: When the MCU receives this signal, it feeds a sheet ofpaper to just before the Registration Sensor (pre-fed position), andwaits for /START.
Chapter 4. Circuit Diagrams 339
PIN SIGNAL DIRECTION DESCTIPTION
B10 /BD MCU⇒Controller Beam Detect: Horizontal synchronization signal. The Controllerbegins to send the video data for one scan line when it receivesthis signal. /BD is sent at the following time intervals.v 300 dpi: 930.4 ms/480 dpi: 581.5 msv 360 dpi: 775.3 ms/600 dpi: 465.2 msv 400 dpi: 697.8 ms/800 dpi: 348.9 ms
B9 /RDY MCU⇒Controller Ready: The MCU holds this signal Low when it can accept /PRFDand /START. When /RDY is High, /PRFD and /START are ignored.
The MCU raises /RDY High when the printer is in one of thefollowing states:1. Call2. Pause/Diagnostic3. Wait4. Misprint5. /PPRDY at High
B8 /SBSY MCU⇒Controller Status Busy: The MCU holds this signal Low when it is sending aStatus.
B7 /PCLK MCU⇒Controller Printer Clock: Clock signal that the MCU supplies and uses forsynchronized transmission of a Status.
B6 /START MCU⇐Controller START: Orders the printer to start the print operation. This signal isvalid only when /RDY is Low.
Chapter 4. Circuit Diagrams 340
PIN SIGNAL DIRECTION DESCTIPTION
B5 /CPRDY MCU⇐Controller Controller Power Ready: Goes Low when the Controller is poweredon and completes initialization. When this signal goes High, theprinter resets to the powered-on state.
v Printer state⇒Standby (ROS: Off, Fuser: On)
When the printer is in the Printing state or the Print Ready state,the printer returns to the Standby state immediately or after theprint operation is completed. When in the Pause state (ROS: Off,Fuser: Off), the printer returns to the Standby state except whenthe Fan is stopped.
(continued)
B5 /CPRDY MCU⇐Controller v Resolution⇒Higher resolution
When the printer has two resolutions and the lower resolution isselected, the resolution returns to the Higher resolution.
v Paper size mismatch detection⇒Enabled
v Fuser temperature⇒Normal temperature
When the high temperature for thick paper is selected, the fusertemperature returns to the normal temperature.
B4 /CMD MCU⇐Controller Command: The Controller sends a Command serially insynchronism with /CCLK.
Chapter 4. Circuit Diagrams 341
MCU ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feeder PWB ⇔Feed Solenoid, No Paper Sensor, and ElectromagneticClutch
MCU PWB FEEDER PWB
FEEDER PWB
FEEDER ASSY FEED SOLENOIDCST NO PAPERSENSOR
ELECTROMAGNETICCLUTCH AUX.
G
G
H
H
I
I
X
Z
M
M
K
K
J
J
Y
W
24VDC
5VDC
4 3 2 1
1 2 3 4
1 2 3 4 5 6 7 8 9
3 2 1 1 2
2 1
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
N.C.
N.C.
24V
DC
TU
RN
ON
(L)
24V
DC
P.U
P
SG
/ NO
PA
PE
R2
(TT
L)
24V
DC
/ FE
ED
2O
N(L
)24
VD
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
P/J203
P/J204
P/J904
P/J205
P/J206
P/J906
P/J201
P/J202
P207
P/J202
P/J20 P/J201 P/J207
A
B
C
CD
BE
AF
F
E
D
24VDC
wXYZ
5VDC5VDC
SW1
PAPERSIZE
SWITCH
SIZESENSE
SW2
SW3
SW4
1st Tray
2nd Tray (Optional)
N.C.
PSIZE2 (TTL)
N.C.
/FEED2 ON(L) 24VDC
/SIZE 3BIT(TTL)
/SIZE 1BIT(TTL)
N.C.
/NO PAPER2 (TTL)
FEEDER CHECK
SVDC
24VDC
RTN
SG
OPTION
/NO PAPER3 (TTL)
OPTION
/SIZE 2BIT(TTL)
/SIZE 4BIT(TTL)
/FEED3 ON(L) 24VDC
TURN (TTL)
PSIZE3 (TTL)
N.C.
hc2m816F
Chapter 4. Circuit Diagrams 342
FEEDER PWB
FEEDER ASSY FEED SOLENOIDCST NO PAPERSENSOR
ELECTROMAGNETICCLUTCH AUX.
G
G
H
H
I
I
X
Z
M
M
K
K
J
J
Y
W
24VDC
5VDC
4 3 2 1
1 2 3 4
1 2 3 4 5 6 7 8 9
3 2 1 1 2
2 1
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
N.C.
N.C.
24V
DC
TU
RN
ON
(L)
24V
DC
P.U
P
SG
/ NO
PA
PE
R3
(TT
L)
24V
DC
/ FE
ED
3O
N(L
)24
VD
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
P/J203
P/J204
P/J904
P/J205
P/J206
P/J906
P/J201
P/J202
P207
24VDC
wXYZ
5VDC5VDC
SW1
PAPERSIZE
SWITCH
SIZESENSE
SW2
SW3
SW4
N.C.
PSIZE2 (TTL)
N.C.
/FEED1 ON(L) 24VDC
/SIZE 3BIT(TTL)
/SIZE 1BIT(TTL)
N.C.
/NO PAPER1 (TTL)
FEEDER CHECK
SVDC
24VDC
RTN
SG
OPTION
/NO PAPER2 (TTL)
OPTION
/SIZE 2BIT(TTL)
/SIZE 4BIT(TTL)
/FEED2 ON(L) 24VDC
TURN (TTL)
PSIZE2 (TTL)
N.C.
MCU PWB FEEDER PWB FEEDER PWB
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
B1
B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A11
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B12
B11
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
A10
A9
A8
A7
A6
A5
A4
A3
A2
A1
B10
B9
B8
B7
B6
B5
B4
B3
B2
B1
P/J202
P/J20 P/J20P/J201 P/J201 P/J207
AA
BB
CC
CC DD
BB EE
AA FF
FF
EE
DD
1st Tray2nd Tray(Optional)
3rd Tray (Optional)
hc2m807F
Chapter 4. Circuit Diagrams 343
Signal names for the Feeder PWB ⇔ Feeder PWB pathSignal Name Description
PSIZE2 (TTL) Selects the Paper Size Switches of Feeder 2. When this signal is HIGH, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.
/FEED2 ON(L) 24VDC Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) isactivated when this signal is LOW, and deactivated when HIGH.
/SIZE 3BIT (TTL) Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 3 is activated.
/SIZE 1BIT (TTL) Signal from the Paper Size Switch 1 of the Feeder selected with the PSIZE2 or 3 signal. Thissignal is LOW when the Paper Size Switch 1 is activated.
/NO PAPER2 (TTL) Signal from the No Paper Sensor 2 (No Paper Sensor of the Feeder 2). This signal is Low whenthe No Paper Sensor 2 is activated.
FEEDER CHECK Signal that indicates the Feeder Configuration.
/NO PAPER3 (TTL) Signal from the No Paper Sensor 3 (No Paper Sensor of the Feeder 2). This signal is Low whenthe No Paper Sensor 3 is activated.
/SIZE 2BIT (TTL) Signal from the Paper Size Switch 2 of the Feeder selected with PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 2 is activated.
/SIZE 4BIT (TTL) Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 4 is activated.
/FEED3 ON(L) 24VDC Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) isactivated when this signal is LOW, and deactivated when HIGH.
TURN (TTL) Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutchis activated when this signal is LOW, and deactivated when HIGH.
PSIZE3 (TTL) Selects the Paper Size Switches of Feeder 3. When this signal is HIGH, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.
Chapter 4. Circuit Diagrams 344
Pin numbers and voltage levels for the Feeder PWB (Feeder1) ⇔ Feeder PWB (Feeder2)path
P202(Feeder1)
P201(Feeder2) Signal Name
Signal Direction
F1: Feeder1
F2: Feeder2 TriggerHighLevel
LowLevel Note
A10 A10 PSIZE2 (TTL) F1⇒F2 Level TTL TTL
A8 A8 /FEED2 ON(L) 24VDC F1⇒F2 Level 24V 0V
A7 A7 /SIZE 3BIT (TTL) F1⇐F2 Level TTL TTL
A6 A6 /SIZE 1BIT (TTL) F1⇐F2 Level TTL TTL
A4 A4 /NO PAPER2 (TTL) F1⇐F2 Level TTL TTL
A3 A3 FEEDER CHECK F1⇐F2 Level * * Analog
B7 B9 /NO PAPER3 (TTL) F1⇐F2 Level TTL TTL
B5 B7 /SIZE 2BIT (TTL) F1⇐F2 Level TTL TTL
B4 B6 /SIZE 4BIT (TTL) F1⇐F2 Level TTL TTL
B3 B5 /FEED3 ON(L) 24VDC F1⇒F2 Level 24V 0V
B2 B4 TURN (TTL) F1⇒F2 Level TTL TTL
B1 B3 PSIZE3 (TTL) F1⇐F2 Level TTL TTL
*: Refer to the description of the detection of the feeder configuration on the next page.
Chapter 4. Circuit Diagrams 345
Pin numbers and voltage levels for the Feeder PWB (Feeder2) ⇔ Feeder PWB (Feeder3)path
P202(Feeder2)
P201(Feeder3) Signal Name
Signal Direction
F2: Feeder2
F3: Feeder3 TriggerHighLevel
LowLevel Note
A10 A10 PSIZE3 (TTL) F2⇒F3 Level TTL TTL
A8 A8 /FEED3 ON(L) 24VDC F2⇒F3 Level 24V 0V
A7 A7 /SIZE 3BIT (TTL) F2⇐F3 Level TTL TTL
A6 A6 /SIZE 1BIT (TTL) F2⇐F3 Level TTL TTL
A4 A4 /NO PAPER3 (TTL) F2⇐F3 Level TTL TTL
A3 A3 FEEDER CHECK F2⇐F3 Level * * Analog
B5 B7 /SIZE 2BIT (TTL) F2⇐F3 Level TTL TTL
B4 B6 /SIZE 4BIT (TTL) F2⇐F3 Level TTL TTL
B3 B5 /FEED3 ON(L) 24VDC F2⇒F3 Level 24V 0V
B2 B4 TURN (TTL) F2⇒F3 Level TTL TTL
*: Refer to the description of the detection of the feeder configuration on the next page.
Chapter 4. Circuit Diagrams 346
Detection of the Feeder configuration through the FEEDER CHECK signal
When no optional Feeder is attached, 5 VDC is divided by the resistance RM on the MCU PWB and theresistance RF on the Feeder PWB of the Feeder 1, and the voltage across the resistance RM appears on theFEEDER CHECK signal. When one or two optional Feeders are added, the resistance RF on the FeederPWB of the added Feeder or Feeders is connected in parallel with the resistance RF of the Feeder 1, and thevoltage across the resistance RM changes according to the number of optional Feeders added. Therefore, theFeeder configuration can be detected from the voltage of the FEEDER CHECK signal.
FEEDER PWB
FEEDERCHECK(TTL)
RF
RM
RF RF
TRAY 1
FEEDER PWB
TRAY 2
FEEDER PWB
TRAY 3
5VDC
SG
MCU PWB
DetectionCircuit
hc2m814F
Chapter 4. Circuit Diagrams 347
Feeder Configuration Feeder 1 Feeder 2 Feeder 3 Voltage (Nominal)
Feeder1 (standard Feeder) not connected 0 VDC
Feeder1 only O 1.60 VDC
One optional Feeder added O O 2.42 VDC
Two optional Feeders added O O O 2.93 VDC
Chapter 4. Circuit Diagrams 348
MCU ⇔ Duplex I/F PWB ⇔ Duplex PWB and FuserCover Switch Duplex PWB ⇔ Dup Stack Sensor, DupCover Switch1, Dup Cover Switch2, Duplex PassSensor, Duplex Motor, and Offset Motor
M
M
MCU PWB
DUPLEXPWB
DUPLEXPWB
DUPLEX UNIT
DUPLEX I/F PWB
DUPLEXMOTOR
DUP STACKSENSOR
DUP COVERSWITCH 1
DUP COVERSWITCH 2
DUPLEX PASSSENSOR
OFFSETMOTOR
COVERSWITCHCOVERSWITCH
P/J190
P/J180
P/J18
P/J182
2 1
1 2
DUPLEXMOTOR
CONTROL
OFFSETMOTORCONTROL
5VDC
5VDC
24VDC
P/J192
P/J184
P/J187
P/J186
P/J183
P/J193
P/J198
P/J197
P/J195
P/J196
DUP B
DUP / A
DUP A
DUP / B
RTN
SG
24VDC
N.C.
/ DUP COVER (TTL)
5VDC
/ FULL (TTL)
/ OCT REV (TTL)
/ OCT ON (TTL)
/ DUP SNS (TTL)
P.UP
SG
/ FULL (TTL)
SG
/ DUP COV 1 (TTL)
MOT +
MOT -
/ DUP SNS (TTL)
SG
A
B
24VDC
24VDC
/ A
/ B
/ DUP COV 2 (TTL)
/ DUP COV (TTL)
hc2m826F
1
9
2
10
3
11
4
12
5
13
6
14
7
15
8
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
1
2
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2
1
2
1
1
2
3
4
5
6
1
2
1
2
1
2
2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 1813
Chapter 4. Circuit Diagrams 349
Signal names for the Duplex I/F PWB ⇔ Duplex PWB pathSignal Name Description
DUP B Duplex Motor exciting signal.
DUP /A Duplex Motor exciting signal.
DUP A Duplex Motor exciting signal.
DUP /B Duplex Motor exciting signal.
/DUP COVER (TTL) Signal from the Dup Cover Switches 1 and 2. This signal is LOW when both the Dup CoverSwitches 1 and 2 are closed and High when the Dup Cover Switch1 or the Dup Cover Switch2 isopen.
/FULL Signal through the Dup Stack Sensor. This signal is LOW when the Dup Stack Sensor isactivated by the stack of delivered printed sheets higher than the predetermined height.
This signal is also used to detect whether the Duplex Unit is installed when printer power isswitched on.
/OCT REV (TTL) Control signal to switch the direction of rotation of the Offset Motor between Normal and Reverse.
LOW: Reverse direction, HIGH: Normal direction
/OCT ON (TTL) Offset Motor Control Signal to switch the Offset Motor on and off.
/DUP SNS (TTL) Signal from the Duplex Pass Sensor. This signal is LOW when the Duplex Pass Sensor isactivated by the paper.
Chapter 4. Circuit Diagrams 350
Pin numbers and voltage levels for the Duplex I/F PWB ⇔ Duplex PWB path
P182 P183 Signal Name
Signal Direction
DIF: Dup I/F PWB
D: Duplex PWB TriggerHighLevel Low Level
1 1 DUP B DIF⇒D Level
9 2 DUP /A DIF⇒D Level
2 3 DUP A DIF⇒D Level
10 4 DUP /B DIF⇒D Level
5 9 /DUP COVER (TTL) DIF⇐D Level TTL TTL
6 11 /FULL DIF⇐D Level * 0V
14 12 /OCT REV (TTL) DIF⇒D Level TTL TTL
7 13 /OCT ON (TTL) DIF⇒D Level TTL TTL
15 14 /DUP SNS (TTL) DIF⇐D Level TTL TTL
* Refer to the description of the Duplex unit detection on the next page.
Signal names for the Duplex PWB ⇔ Offset Motor pathSignal Name Description
MOT+, MOT- Offset Motor drive power.
Normal rotation: When MOT+ is 24 VDC and MOT- is 0 VDC.
Reverse rotation: When MOT+ is 0 VDC and MOT- is 24 VDC.
Chapter 4. Circuit Diagrams 351
Pin numbers and voltage levels for the Duplex PWB ⇔ Offset Motor path
P186 P196 Signal Name
Signal Direction
D: Duplex PWB
OM: Offset Motor Trigger High Level Low Level
1 1 MOT+ D ⇔ OM Level 24 VDC 0 V
2 2 MOT- D ⇔ OM Level 24 VDC 0 V
Chapter 4. Circuit Diagrams 352
HCF LVPS⇔ Components, HCF LVPS ⇔ FEEDER PWB
RIGHT HAND COVEROPEN SWITCH
LEFT HAND COVEROPEN SWITCH
TRANSPORT MOTOR
SENSOR
TRAY SET SENSOR 1
PAPER LEVEL SENSOR
ENCODER
FEEDMOTORCONTROL
NO PAPER SENSOR
UPPER LIMIT SENSOR
TRAY SET SENSOR 2
SIZE SENSOR
NEAR EMPTY SENSOR
LOWER POSITION SENSOR
LIFT UP MOTOR
P/J:M1
P/J:S2
P/J:S7
P/J:S11
P/J:S3
P/J:P1
P/J:S1
P/J:XS4
P/J:P2
P/J:S10
P/J:S6
P/J:S12
P/J:S9
P/J:M2
P/J:S8
LIFT UPMOTORCONTROL
CPU
SG
P/J:XS3RXDTXDSGSG
FEEDER CHECK
BaseEngine
or
2ND TRAY
(+)( - )
13
13
13
21
13
321
54
123
123
1234
12
123
12
12
GNDGND
FG
DC21
DC22
DC22
SWHD
SGSWPL(TTL)
SGSWPSZ(TTL)
DC21SWHU1
SWHU1SWHU2
+5VDC
LSPE(TTL)
SG
DC11DC12
+5VDC
ENCOD(TTL)
SG
+5VDC
LSPL(TTL)
SG
SWCPR(TTL)
SG
+5VDC
LSPEX(TTL)
SG
SM1
SM2
SM3
SM4
SWDO1(TTL)
SWDO(TTL)
SWDO1(TTL)
SG
FEED MOTOR
141612139
12345
P/J:XS110912
56
78
34
P/J:XS2
1211
2526
12
345
678
222324
910
131415
18192021
1617
2728
TRANSPORTMOTORCONTROL
MAIN SWITCHAC to DC
SERVICE CONNECT
AC INLET
LVPS
M
M
M
This is an internal wiring of the FEED ROLLER KIT,therefore the P/J No. and Pin No. are omitted.hc2m089F
Chapter 4. Circuit Diagrams 353
Signal names for the HCF LVPS ⇔ ComponentsSignal Name Description
DC21, DC22 DC21, DC22
Elevator Motor drive power
Elevator rotation: When DC21 is 0VDC and DC22 is more then 22VDC.
Lift down rotation: When DC21 is more then 22VDC and DC22 is 0VDC.
SWHD SWITCH HAZARD DOWN
This switch interrupts the motor current if the elevator is in the down position (fill position).
SWPL (TTL) SWITCH PAPER LOW
This signal indicates the Paper low stack.
LSPE (TTL) LIGHT SENSOR PAPER END
This signal indicates if the last sheet fed.
ENCOD (TTL) ENCODER SIGNAL
This signal controls the Feed Motor. It works as speed regulator.
DC11, DC12 DC11, DC12
Feed Motor drive power, 0 / 24VDC (PWM SIGNAL)
LSPL (TTL) LIGHT SENSOR PAPER LEVEL
This signal shows if the paper stack is in feed position.
SWCPR (TTL) SWITCH CARRIAGE PRESENT
This signal indicates if the carriage is in or out.
Chapter 4. Circuit Diagrams 354
Signal Name Description
LSPEX (TTL) LIGHT SENSOR PAPER EXIT
This signal indicates that a paper is in the transport.
SM1 TRANSPORT MOTOR/A
Transport Motor exciting signal.
SM2 TRANSPORT MOTOR A
Transport Motor exciting signal.
SM3 TRANSPORT MOTOR/B
Transport Motor exciting signal.
SM4 TRANSPORT MOTOR B
Transport Motor exciting signal.
SWDO (TTL)
SWDO1 (TTL)
SWITCH DOOR OPEN
This signal indicates an open rear cover.
SWHU1
SWHU2
SWITCH HAZARD UP
This safety switch interrupts the motor current if the Paper Level Sensor does not work and theelevator moves up too much.
SWPSZ (TTL) SWITCH PAPER SIZE
This signal displays the used paper size in the HCF.
Chapter 4. Circuit Diagrams 355
Signal names for the HCF LVPS ⇔ FEEDER PWBSignal Name Description
TXD TRANSMITTED DATA
Data connection Base Engine to HCF.
RXD RECEIVED DATA
Data connection HCF To Base Engine.
FEEDER CHECK FEEDER CHECK
Signal that indicates the Feeder / HCF Configuration.
Chapter 4. Circuit Diagrams 356
Pin numbers and voltage levels for the HCF LVPS ⇔ Components
P: P: Signal Name Signal Direction TriggerHighLevel Low Level
XS1-1 M1-(+) DC21 Floating Signal (see note 1) LEVEL 0V 24V
XS1-2 M1-(-) DC22 Floating Signal (see note 1) LEVEL 24V 0V
XS1-3 S1-1 SG Power - 0V
XS1-4 S1-3 SWPL (TTL) Near Empty Sensor → LVPS LEVEL TTL TTL
XS1-5 S2-1 DC22 Floating Signal (see note 1) LEVEL 24V 0V
XS1-6 S2-3 SWHD Floating Signal (see note 1) LEVEL 24V 0V
XS1-7 S3-1 SG Power - 0V
XS1-8 S3-3 SWPSZ (TTL) Paper Size Sensor → LVPS LEVEL TTL TTL
XS1-9 SG Power - 0V
XS1-10 SG Power - 0V
XS2-1 P1-5 DC11 LVPS → Feed Motor LEVEL 24V 0V (seenote 2)
XS2-2 P1-4 DC12 LVPS → Feed Motor LEVEL 24V 0V (seenote 2)
XS2-3 P1-3 +5V Power - 5V
XS2-4 P1-2 LSPE (TTL) No Paper Sensor → LVPS LEVEL TTL TTL
XS2-5 P1-1 SG Power - 0V
XS2-6 P2-1 +5V Power - 5V
XS2-7 P2-2 ENCOD (TTL) Encoder → LVPS LEVEL TTL TTL
XS2-8 P2-3 SG Power - 0V
XS2-9 S6-1 SWCPR (TTL) Tray Set Sensor 1 → LVPS LEVEL TTL TTL
Chapter 4. Circuit Diagrams 357
P: P: Signal Name Signal Direction TriggerHighLevel Low Level
XS2-10 S6-2 SG Power - 0V
XS2-11 S7-1 SWHU1 Floating Signal (see note 1) LEVEL 24V 0V
XS2-12 S7-2 DC21 Floating Signal (see note 1) LEVEL 24V 0V
XS2-13 S8-1 +5V Power - 5V
XS2-14 S8-2 LSPEX (TTL) Sensor → LVPS LEVEL TTL TTL
XS2-15 S8-3 SG Power - 0V
XS2-16 S9-1 SWDO1 Left Hand Cover OpenSwitch → Right Hand CoverOpen Switch
LEVEL TTL TTL
XS2-17 S9-2 SG Power - 0V
XS2-18 M2-1 SM1 LVPS → Transport Motor LEVEL 24V 0V (seenote 3)
XS2-19 M2-2 SM2 LVPS → Transport Motor LEVEL 24V 0V (seenote 3)
XS2-20 M2-3 SM3 LVPS → Transport Motor LEVEL 24V 0V (seenote 3)
XS2-21 M2-4 SM4 LVPS → Transport Motor LEVEL 24V 0V (seenote 3)
XS2-22 S10-1 +5V Power - 5V
XS2-23 S10-2 LSPL (TTL) Paper Level Sensor → LVPS LEVEL TTL TTL
XS2-24 S10-3 SG Power - 0V
XS2-25 S11-1 SWHU1 Floating Signal (see note 1) LEVEL 24V 0V
XS2-26 S11-3 SWHU2 Floating Signal (see note 1) LEVEL 24V 0V
Chapter 4. Circuit Diagrams 358
P: P: Signal Name Signal Direction TriggerHighLevel Low Level
XS2-27 S12-1 SWDO1 Left Hand Cover OpenSwitch → Right Hand CoverOpen Switch
LEVEL TTL TTL
XS2-28 S12-2 SWDO Right Hand Cover OpenSwitch → LVPS
LEVEL TTL TTL
Notes:1. This signal is used to stop the Elevator Motor when it is not responding. It is connected to the Drive Power cable and the
Serial port (no direction).2. PWM (Pulse Width Modulation) Signal3. Rectangle Signal
Chapter 4. Circuit Diagrams 359
Chapter 5. LocationsQuick Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361Covers and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
Clutches, Solenoids, Motors, and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367Printed Wiring Boards (PWBs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Mechanical and Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
© Copyright IBM Corp. 1998 360
Quick PathTo... Location Tables with Links to Illustrations, to the Parts
Catalog, to Wiring and Pinout Diagrams, and to Removals
Assemblies Table 59 on page 362
Clutches Table 60 on page 364
Connectors Table 61 on page 367
Covers Table 59 on page 362
Fans Table 60 on page 364
Mechanical Table 65 on page 390
Motors Table 60 on page 364
Paper Path Figure 23 on page 392
Printed Wiring Boards (PWBs) / Power Supplies Table 62 on page 380
Sensors Table 63 on page 384
Solenoids Table 60 on page 364
Switches Table 64 on page 386
Chapter 5. Locations 361
Covers and AssembliesTable 59. Assemblies
Unit Cover or Assembly Figure Parts Catalog Asm.– Index
Printer
Operator Panel Fig. 5, p. 363 1–18, p. 548
Top Cover Fig. 5, p. 363 1–14, p. 548
Tray 1 Fig. 5, p. 363 2, p. 550
Auxiliary Tray Fig. 5, p. 363 5, p. 557
Fuser Cover Fig. 5, p. 363 8–1, p. 564
Rear Cover Fig. 5, p. 363 3–5, p. 553
Serial Number Fig. 5, p. 363
Power Cord Socket Fig. 5, p. 363 12–4, p. 572
Power Switch Fig. 5, p. 363 12–4, p. 572
Side Cover Fig. 5, p. 363 1–10, p. 548
Duplex Duplex Unit Fig. 5, p. 363 30, 31, p. 652, 655
Duplex Covers Fig. 5, p. 363 30-5, 30-6, p. 652
Trays Tray 2/3 Fig. 5, p. 363 20, 21, p. 697, 700
2000-Sheet Input Drawer Fig. 5, p. 363 40, 41, 42, p. 774, 776, 778
Chapter 5. Locations 362
500-sheet paper tray(Tray 1)
Auxiliarytray
Operator panel
PowerswitchPower
cord socket
Printercontrollerboard
500-sheetpaper trays(Tray 2/Tray 3)(optional)
Duplex unit(optional)
Duplex covers
Top cover Fusercover
Rearcover
Side cover
2000-sheetinput drawer(optional)
X12345
Serialnumber
hc2m221F
Figure 5. Covers and Assemblies
Chapter 5. Locations 363
Electrical Components
Clutches, Solenoids, Motors, and FansTable 60. Clutches, Solenoids, Motors, and Fans
Unit Clutch, Solenoid, Motor, or Fan Figure / Reference Parts Catalog Asm.–Index
WiringDiagram
PinoutDiagram
Printer
CL1 Registration Clutch Fig. 6, p. 365 / 6 10–9, p. 570 p. 322 p. 324
CL2 Electromagnetic (Turn) Clutch Fig. 6, p. 365 / 5 4–9, p. 555 p. 325 p. 328
SL1 Feed Solenoid Fig. 6, p. 365 / 4 4–8, p. 555 p. 325 p. 328
SL2 Pick Up Solenoid Fig. 6, p. 365 / 2 6–17, p. 559 p. 322 p. 324
Fan Fig. 6, p. 365/ 1 12–3, p. 575 p. 311 p. 311
Main motor Fig. 6, p. 365/ 3 10–6, p. 570 p. 329 p. 330
Trays CL2 Tray 2/3 Electromagnetic (Turn)Clutch
Fig. 7, p. 366 / 7 21–19, p. 700 p. 342 p. 342
SL1 Tray 2/3 Feed Solenoid Fig. 7, p. 366 / 8 21–18, p. 700 p. 342 p. 342
Duplex Offset motor Fig. 8, p. 366/ 9 30–21, p. 652 p. 349 p. 352
Duplex motor Fig. 8, p. 366/ 10 31–23, p. 655 p. 349 p. 351
HCF Elevator motor Fig. 9, p. 367/ 11 41–10, p. 776 p. 353 p. 357
Feed motor Fig. 9, p. 367/ 12 42–28, p. 778 p. 353 p. 357
Transport motor Fig. 9, p. 367/ 13 42–21, p. 778 p. 353 p. 357
Chapter 5. Locations 364
hc2m222F
23
1
456
Figure 6. Clutches, Solenoids, Motors, and Fans: Printer
Chapter 5. Locations 365
HC2M122F
7 8
Figure 7. Clutches, Solenoids, Motors, and Fans: Trays
HC2M118F
10
9
Figure 8. Clutches, Solenoids, Motors, and Fans: Duplex
Chapter 5. Locations 366
ConnectorsTable 61. Connectors, Printer
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
11 Fig. 11, p. 375 / C4 MCU PWB... LVPS Assembly p. 311 p. 311
12 Fig. 11, p. 375 / B3 MCU PWB... ROS Assembly p. 315 p. 317
13 Fig. 11, p. 375/ B4 MCU PWB... High Harness Assembly (Registration Clutch,Registration Sensor, No Paper Sensor, and Feed Solenoid)
p. 322 p. 324
14 Fig. 11, p. 375 / B3 MCU PWB... High Harness Assembly (Full Stuck Sensor,Temperature Sensor, and Exit Sensor)
p. 313 p. 314
15 Fig. 11, p. 375 / B4 MCU PWB... HVPS Assembly p. 319 p. 321
16 Fig. 11, p. 375 / B3 MCU PWB... Main Motor p. 329 p. 330
11
12
13
hc2m130F
Figure 9. Clutches, Solenoids, Motors, and Fans: HCF
Chapter 5. Locations 367
Table 61. Connectors, Printer (continued)
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
17 Fig. 11, p. 375 / C2 MCU PWB... CRU Sensor Assembly p. 315 p. 317
18Fig. 11, p. 375 / B3 MCU PWB... Duplex Interface PWB
p. 332 p. 332Fig. 11, p. 375 / B3 MCU PWB... Fuser Cover Switch (if no Duplex Interface
PWB)
19 Fig. 11, p. 375 / B4 MCU PWB... diagnostic tool console panel (open connector) p. 310 p. 310
20 Fig. 11, p. 375 / C4 MCU PWB... Feeder PWB p. 325 p. 328
21 Fig. 11, p. 375 / C4 MCU PWB... Interlock Switch p. 311 p. 311
22 Fig. 11, p. 375 / B4 MCU PWB... Toner Sensor p. 331 p. 331
23 Fig. 11, p. 375 / B4 Open connector for producing test print output (two pins) p. 310 p. 310
31 Fig. 11, p. 375 / B4 MCU PWB... ESS PWB p. 337 p. 338
112 Fig. 11, p. 375 / A2 ROS Assembly (LD Assembly)... MCU PWB p. 315 p. 317
113 Fig. 11, p. 375 / A1 ROS Assembly (SOS PWB)... MCU PWB p. 315 p. 317
114 Fig. 11, p. 375 / A2 ROS Assembly (Scanner Assembly)... MCU PWB p. 315 p. 317
121 Fig. 11, p. 375 / B3 LVPS Assembly... LMCU PWB p. 311 p. 311
122 Fig. 11, p. 375 / C3 LVPS Assembly... Fan p. 311 p. 311
123 Fig. 10, p. 373 / B3 LVPS Assembly... Interlock Switch p. 311 p. 311
124 Fig. 11, p. 375 / C2 LVPS Assembly... High Harness Assembly Heater Rod p. 311 p. 311
126 Fig. 11, p. 375 / C3 LVPS Assembly... ESS p. 337 p. 338
127 Fig. 11, p. 375 / C3 Open connector (plug) on LVPS Assembly board p. 311 p. 311
Chapter 5. Locations 368
Table 61. Connectors, Printer (continued)
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
131 Fig. 11, p. 375 / C1 Registration Clutch Assembly... High Harness Assembly(MCU PWB)
p. 322 p. 324
132 Fig. 10, p. 373 / C3 Registration Sensor... High Harness Assembly (MCU PWB) p. 322 p. 324
134 Fig. 10, p. 373 / C3 MSI No Paper Sensor... MCU PWB p. 322 p. 324
135 Fig. 10, p. 373 / C2 Feed Solenoid... High Harness Assembly (MCU PWB) p. 322 p. 324
137 Fig. 10, p. 373 / C2 MSI Bracket Assembly (MSI N/P Harness)... High HarnessAssembly (MCU PWB)
p. 322 p. 324
142 Fig. 10, p. 373 / A2 Fuser Assembly (Heater Assembly)... Transport ChuteAssembly (High Harness Assembly (MCU PWB)
p. 313 p. 314
143 Fig. 10, p. 373 / A3 Temperature Sensor Assembly... Fuser Harness (MCUPWB)
p. 313 p. 314
144 Fig. 10, p. 373 / A3 Exit Sensor... MCU PWB p. 313 p. 314
145 Fig. 10, p. 373 / A3 Full Stuck Sensor... MCU PWB p. 313 p. 314
151 Fig. 11, p. 375 / B3 HVPS Assembly... MCU PWB p. 319 p. 321
171 Fig. 11, p. 375 / A1 CRU Sensor Assembly internals... MCU PWB p. 315 p. 317
180 Fig. 11, p. 375 / A1 Duplex Interface PWB... Fuser Cover Switch p. 332 p. 333
182 Fig. 11, p. 375 / C4,Fig. 13, p. 377 / B2 Duplex Interface PWB... Duplex Unit (Duplex Cable) p. 349 p. 351
183 Fig. 13, p. 377 / B2 Duplex Cable... Duplex PWB p. 349 p. 351
184 Fig. 13, p. 377 / A2 Duplex Sensor Harness... Duplex PWB p. 349 p. 349
186 Fig. 13, p. 377 / A2 Offset Motor... Duplex PWB p. 349 p. 352
Chapter 5. Locations 369
Table 61. Connectors, Printer (continued)
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
187 Fig. 13, p. 377 / A2 Duplex Motor Harness... Duplex PWB p. 349 p. 349
190 Fig. 11, p. 375 / C4 Fuser Cover Switch... Duplex Interface PWB p. 332 p. 333
192 Fig. 13, p. 377 / A3 Duplex Sensor Harness... Duplex Stack Sensor p. 349 p. 349
193 Fig. 13, p. 377 / A2 Duplex Sensor Harness... Duplex Cover Switch 1 p. 349 p. 349
195 Fig. 13, p. 377 / A4 Duplex Motor Harness... Duplex Pass Sensor p. 349 p. 349
196 Fig. 13, p. 377 / A2 Offset Motor p. 349 p. 352
197 Fig. 13, p. 377 / A3 Duplex Motor Harness... Duplex Motor p. 349 p. 349
198 Fig. 13, p. 377 / B2 Duplex Sensor Harness... Duplex Cover Switch 1 p. 349 p. 349
201 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / A3 Feeder PWB... MCU PWB p. 342 p. 345
202 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / A3 Feeder PWB... Tray Lower1 Harness p. 342 p. 346
203 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / B3
Feeder PWB... Feeder Harness (Turn Clutch, No PaperSensor, and Feed Solenoid)
p. 342 p. 342
204 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B2 Feed Solenoid... MCU PWB p. 342 p. 342
205 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B3 Cassette No Paper Sensor... MCU PWB p. 342 p. 342
206 Fig. 11, p. 375 / C1,Fig. 12, p. 376 / B2,
Electromagnetic Clutch... MCU PWB p. 342 p. 342
Chapter 5. Locations 370
Table 61. Connectors, Printer (continued)
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
207Fig. 10, p. 373 / C1,Fig. 12, p. 376 / A3,B3
Tray Lower1 Harness... option’s Feeder Assembly (Plugs) p. 342 p. 342
221 Fig. 10, p. 373 / C3 Toner Sensor... MCU PWB p. 331 p. 331
222 Fig. 10, p. 373 / C2 MSI Bracket Assembly (Toner Sensor Harness)... TonerRelay Harness (MCU PWB)
p. 331 p. 331
421 Fig. 10, p. 373 / A1 Console Assembly... Controller p. 334 p. 336
904 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B2 Feed Solenoid... MCU PWB p. 342 p. 342
906 Fig. 12, p. 376 / B2 MCU PWB ... Electromagnetic Clutch p. 342 p. 342
922 Fig. 10, p. 373 / C2 Toner Sensor... MCU PWB p. 331 p. 331
935 Fig. 10, p. 373 / C2 Feed Solenoid... MCU PWB p. 322 p. 324
937 Fig. 10, p. 373 / C2 MSI No Paper Sensor... MCU PWB p. 322 p. 324
942 Fig. 10, p. 373 / A2 Fuser Harness... Heater Assembly p. 313 p. 314
943 Fig. 10, p. 373 / A3 Fuser Harness internal connector p. 313 p. 314
CR Fig. 11, p. 375 / A3 HVPS Assembly... CRU Guide Assembly Left (Power supplyfor BCR)
p. 319 p. 321
DB Fig. 11, p. 375 / A2 HVPS Assembly... CRU Guide Assembly Left (Power supplyfor magnet roll)
p. 319 p. 321
DTS Fig. 11, p. 375 / A3 HVPS Assembly... High Harness Assembly (Power supplyfor Detack Saw)
p. 319 p. 321
M1 Fig. 14, p. 378 / C1 Harness... Lift Up Motor p. 353 p. 357
Chapter 5. Locations 371
Table 61. Connectors, Printer (continued)
Connector WiringDiagram
PinoutDiagramP/J Figure / Grid From... To...
M2 Fig. 14, p. 378 / C4 Flat Harness... Transport Motor p. 353 p. 357
P1 Fig. 14, p. 378 / A3 Flat Harness... Kit Feed Roller p. 353 p. 357
P2 Fig. 14, p. 378 / A3 Flat Harness... Kit Feed Roller p. 353 p. 357
S1 Fig. 14, p. 378 / C1 Harness... Near Empty Sensor p. 353 p. 357
S2 Fig. 14, p. 378 / C1 Harness... Lower Position Sensor p. 353 p. 357
S3 Fig. 14, p. 378 / C1 Harness... Size Sensor p. 353 p. 357
S6 Fig. 14, p. 378 / A4 Flat Harness... Tray Set Sensor 1 p. 353 p. 357
S7 Fig. 14, p. 378 / A4 Flat Harness... Tray Set Sensor 2 p. 353 p. 357
S8 Fig. 14, p. 378 / C4 Flat Harness... Sensor p. 353 p. 357
S9 Fig. 14, p. 378 / C4 Flat Harness... Left Hand Cover Open Switch p. 353 p. 357
S10 Fig. 14, p. 378 / A3 Flat Harness... Paper Level Sensor p. 353 p. 357
S11 Fig. 14, p. 378 / A3 Flat Harness... Upper Limit Sensor p. 353 p. 357
S12 Fig. 14, p. 378 / B3 Flat Harness... Right Hand Cover Open Switch p. 353 p. 357
TR Fig. 11, p. 375 / B3 HVPS Assembly... High Harness Assembly (Power supplyfor BTR)
p. 319 p. 321
XS1 Fig. 14, p. 378 / A2 LVPS... Harness p. 353 p. 357
XS2 Fig. 14, p. 378 / A2 LVPS... Flat Harness p. 353 p. 357
XS3 Fig. 14, p. 378 / A2 LVPS... Kit Connector p. 353 p. 353
XS4 Fig. 14, p. 378 / A1 Base Engine... Kit Connector p. 353 p. 353
Chapter 5. Locations 372
1 2 3 4
1 2 3 4
A
B
C
A
B
C
HC2M111F
J421
J142, J942 J143, J943
J145J144
J207J135, J935
J222, J922J137, J937
J221J134
J132
Figure 10. Connectors, Printer
Chapter 5. Locations 373
Chapter 5. Locations 374
HC2M112F
J114J112
DB
CR
DTS
J151
TR
J123
J202
J201
J121
J203
J126J127
J122
J124J205J204,J904
J206J131
J31
J11
J17
J14
J18
J16
J23
J15
J19
J22
J13
J20
J12
J21
J182J190
J113
J180 J171
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Figure 11. Connectors, Printer
Chapter 5. Locations 375
hc2m126F
J201 J202J207
P207
J203J205
J204, J904
J206, J906
1 2 3 4
A
B
A
B
Figure 12. Connectors, Trays
Chapter 5. Locations 376
hc2m117F
J184
J187
J183
J186J193
J196
J197J192
J195
J198P182
1 2 3 4
A
B
A
B
Figure 13. Connectors, Duplex
Chapter 5. Locations 377
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m128F
XS4
XS1XS3
XS2
S2M1
S1S3
S12
S11
P1S10
P2 S6S7
S9
S8
M2
Figure 14. Connectors, HCF
Chapter 5. Locations 378
Chapter 5. Locations 379
Printed Wiring Boards (PWBs)Table 62. Printed Wiring Boards (PWBs)
Unit PWB Figure /Reference
Parts CatalogAsm.– Index
WiringDiagram
(Grid)
PinoutDiagram
(Grid)Removal
Printer Control panel (console) Fig. 15, p. 381 / 1 1–18, p. 548 p. 334 p. 336 p. 418
Controller PWB Fig. 15, p. 381 / 2 13–6, p. 578 p. 337 p. 338 p. 537
HVPS Fig. 15, p. 381 / 3 12–11, p. 575 p. 319 p. 321 p. 532
Feeder PWB Fig. 15, p. 381 / 4 3–1, p. 553 p. 342 p. 342 p. 420
LVPS Fig. 15, p. 381 / 5 12–4, p. 575 p. 311 p. 311 p. 521
MCU PWB Fig. 15, p. 381 / 7 12–8/9, p. 575 p. 310 p. 310p. 526 orp. 529
Duplex Interface PWB Fig. 15, p. 381/ 6 12–6, p. 575 p. 349 p. 349 p. 524
Duplex Duplex PWB Fig. 17, p. 382 / 9 30–10, p. 652 p. 349 p. 349 p. 627
Feeder Tray 2/3 Feeder PWB Fig. 16, p. 381 / 8 20–11, p. 697 p. 342 p. 342 p. 674
HCF LVPS Fig. 18, p. 383 / 10 42–25, p. 778 p. 353 p. 357 p. 674
Chapter 5. Locations 380
HC2M116F
1
2
3
4
56
7
Figure 15. Printed Wiring Boards (PWBs): Printer
8
HC2M125F
Figure 16. Printed Wiring Boards (PWBs): Trays
Chapter 5. Locations 381
HC2M121F
9
Figure 17. Printed Wiring Boards (PWBs): Duplex
Chapter 5. Locations 382
hc2m129F
10
Figure 18. Printed Wiring Boards (PWBs): HCF
Chapter 5. Locations 383
SensorsTable 63. Sensors
Unit Sensor Figure /Reference
Parts CatalogAsm.– Index
WiringDiagram
(Grid)
PinoutDiagram
(Grid)Removal
Printer
CRU sensor Fig. 19, p. 387 / 1 11–15, p. 572 p. 315 p. 317 p. 503
Full stack sensor Fig. 19, p. 387/ 2 8–7, p. 564 p. 313 p. 314 p. 487
Exit sensor Fig. 19, p. 387/ 3 8–25, p. 564 p. 313 p. 314 p. 487
Temperature sensor Fig. 19, p. 387/ 4 9–9, p. 567 p. 313 p. 314 p. 487
Registration sensor Fig. 19, p. 387/ 5 7–6, p. 562 p. 322 p. 324 p. 484
Auxiliary tray no-paper sensor Fig. 19, p. 387/ 6 5–9, p. 557 p. 322 p. 324 p. 460
Toner sensor Fig. 19, p. 387/ 7 5–13, p. 557 p. 331 p. 331 p. 462
Cassette no-paper sensor Fig. 19, p. 387/ 10 3–11, p. 553 p. 342 p. 342 p. 430
DuplexDuplex stack sensor Fig. 21, p. 388 / 14 30–17, p. 652 p. 349 p. 349 p. 635
Duplex pass sensor Fig. 21, p. 388/ 13 30–13, p. 652 p. 349 p. 349 p. 633
Feeder Tray 2/3 cassette no-paper sensor Fig. 20, p. 388 / 12 20–21, p. 697 p. 342 p. 342 p. 683
Chapter 5. Locations 384
Table 63. Sensors (continued)
Unit Sensor Figure /Reference
Parts CatalogAsm.– Index
WiringDiagram
(Grid)
PinoutDiagram
(Grid)Removal
HCF
Near empty sensor Fig. 22, p. 389 / 17 41–11, p. 776 p. 353 p. 353 p. 731
Size sensor Fig. 22, p. 389 / 18 41–15, p. 776 p. 353 p. 353 p. 735
Lower position sensor Fig. 22, p. 389 / 19 41–12, p. 776 p. 353 p. 353 p. 733
Sensor Fig. 22, p. 389 / 27 42–10, p. 778 p. 353 p. 353 p. 745
Upper limit sensor Fig. 22, p. 389 / 23 42–11, p. 778 p. 353 p. 353 p. 750
No paper sensor Fig. 22, p. 389 / 25 42–28, p. 778 p. 353 p. 353 p. 747
Tray set sensor 1 Fig. 22, p. 389 / 21 42–18, p. 778 p. 353 p. 353 p. 756
Tray set sensor 2 Fig. 22, p. 389 / 20 42–19, p. 778 p. 353 p. 353 p. 756
Paper level sensor Fig. 22, p. 389 / 22 42–12, p. 778 p. 353 p. 353 p. 752
Chapter 5. Locations 385
SwitchesTable 64. Switches
Unit Switch Figure /Reference
Parts CatalogAsm.– Index
WiringDiagram
(Grid)
PinoutDiagram
(Grid)Removal
PrinterInterlock switch Fig. 19, p. 387 / 8 12–1, p. 575 p. 311 p. 311 p. 513
Fuser cover switch Fig. 19, p. 387/ 9 12–2, p. 575 p. 332 p. 332 p. 516
DuplexDuplex cover switch 1 Fig. 21, p. 388 / 15 30–11, p. 652 p. 349 p. 349 p. 629
Duplex cover switch 2 Fig. 21, p. 388/ 16 30–12, p. 652 p. 349 p. 349 p. 631
Trays Paper size switch (on feederPWB)
Fig. 20, p. 388 / 11 20–11, p. 697 p. 342 p. 342 p. 674
HCFRight hand cover open switch Fig. 22, p. 389 / 24 42–9, p. 778 p. 353 p. 353 p. 743
Left hand cover open switch Fig. 22, p. 389 / 26 42–20, p. 778 p. 353 p. 353 p. 758
Chapter 5. Locations 386
hc2m223F
7
1 2
34
5
6
8
9
10
Figure 19. Sensors and Switches: Printer
Chapter 5. Locations 387
12
hc2m224F
11
Figure 20. Sensors and Switches: Trays
hc2m225F
13
14
15
16
Figure 21. Sensors and Switches: Duplex
Chapter 5. Locations 388
17
hc2m127F
18 19
20212223
24
2526
27
Figure 22. Sensors and Switches: HCF
Chapter 5. Locations 389
Mechanical and MiscellaneousTable 65. Mechanical and Miscellaneous Items
Unit Item Figure / Reference Parts Catalog Asm.– Index
Printer
Laser Unit (ROS) Fig. 24, p. 393 / 28 11–20, p. 572
Fuser Assembly Fig. 24, p. 393 / 29 8, p. 564
BTR Roll Fig. 24, p. 393 / 30 6–1, p. 559
EP Cartridge Fig. 24, p. 393 / 31 11–40, p. 572
Pick Up Roller Fig. 23, p. 392 / 1 6–8, p. 559
Metal Registration Roller Fig. 23, p. 392 / 2 7–10, p. 562
Rubber Registration Roller Fig. 23, p. 392 / 3 7–11, p. 562
Drum (part of EP Cartridge) Fig. 23, p. 392 / 4 11–40, p. 572
Heat Roller (part of Fuser Assembly) Fig. 23, p. 392 / 5 9–10, p. 567
Offset/Exit Roller Fig. 23, p. 392 / 6 31–9, p. 655
Pressure Roll (part of Fuser Assembly) Fig. 23, p. 392 / 12 9–15, p. 567
BTR Assembly Fig. 23, p. 392 / 13 6–1, p. 559
Rear Roll Assembly Fig. 23, p. 392 / 16 4–11, p. 555
Turn Roll Assembly Fig. 23, p. 392 / 17 4–10, p. 555
Chapter 5. Locations 390
Table 65. Mechanical and Miscellaneous Items (continued)
Unit Item Figure / Reference Parts Catalog Asm.– Index
Duplex
Exit Pinch Roller Fig. 23, p. 392 / 7 30–5, p. 652
Offset Pinch Roller Fig. 23, p. 392 / 8 31–7, p. 652
Offset Roller Fig. 23, p. 392 / 9 31–8, p. 655
Duplex Upper Roller Fig. 23, p. 392 / 10 31–11, p. 655
Duplex Upper Pinch Roller Fig. 23, p. 392 / 11 30–5, p. 652
Duplex Lower Roller Fig. 23, p. 392 / 14 31–12, p. 655
Duplex Lower Pinch Roller Fig. 23, p. 392 / 15 30–6, p. 652
Trays
Tray 1 Pinch Roller Fig. 23, p. 392 / 18 4–11, p. 555
Tray 1 Turn Roller Assembly Fig. 23, p. 392 / 19 4–10, p. 555
Tray 1 Feed Roller Fig. 23, p. 392 / 20 4–1, p. 555
Tray 2 Pinch Roller Fig. 23, p. 392 / 21 20–1, p. 700
Tray 2 Turn Roller Assembly Fig. 23, p. 392 / 22 21–20, p. 700
Tray 2 Feed Roller Fig. 23, p. 392 / 23 21–11, p. 700
HCF
Pinch roll Fig. 23, p. 392 / 24 42–5, p. 778
Transport roll Fig. 23, p. 392 / 25 42–7, p. 778
Pinch roll Fig. 23, p. 392 / 26 42–5, p. 778
Feed roll Fig. 23, p. 392 / 27 42–14, p. 778
Chapter 5. Locations 391
hc2m785F
FRONT
1
34
56
7 8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
2
Figure 23. Mechanical
Chapter 5. Locations 392
hc2m226F
2829
30
31
Figure 24. Miscellaneous
Chapter 5. Locations 393
Chapter 6. Removal Procedures, AdjustmentsFuser Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Left Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
Right Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
Left Side Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
Left Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
Right Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
Front Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415
Pop Up Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417
© Copyright IBM Corp. 1998 394
Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419
Feeder PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Turn In Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
Turn Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425
Cassette Guide Assembly Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428
Cassette No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .430Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .430Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431
Cassette Guide Assembly Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435
Cassette No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437
Feed Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438You may follow either procedure A or B.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438Procedure A Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Procedure B Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
Chapter 6. Removal Procedures, Adjustments 395
Feed Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .444
Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448
Electromagnetic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
Turn Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452
Rear Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454
Front Tray Assembly and Front in Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456
Auxiliary Tray Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
Auxiliary Tray No Paper Sensor/Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461
Toner Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463
Front Bottom Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465
Chapter 6. Removal Procedures, Adjustments 396
BTR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
Transport Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Pick Up Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475
Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Retard Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482
Registration Sensor/Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486
Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488
Main Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490
Paper Handling Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
Registration Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496
Chapter 6. Removal Procedures, Adjustments 397
Main Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499
Pop Up Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502
CRU Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505
CRU Guide Assembly Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .507Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508
CRU Guide Assembly Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .510Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .510Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .515
Fuser Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .517
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519
LVPS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523
Duplex Interface PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525
Chapter 6. Removal Procedures, Adjustments 398
MCU PWB without MCU Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527
MCU PWB with MCU Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .529Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .536
Controller PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .538
Controller PWB SIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540
Network Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542
Chapter 6. Removal Procedures, Adjustments 399
Fuser Cover AssemblyAsm-Index: 1-1, page 548.
hc2m957f
FRONT1
64
2
5 3
Figure 25. Fuser Cover Assembly Removal
Chapter 6. Removal Procedures, Adjustments 400
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove duplex unit (See page 615), if supplied.
3. Open the fuser cap cover (1) (Asm-Index: 1-3, page 548).
4. Lift up the fuser cap cover and remove from the fuser cover (2) (Asm-Index: 1-2, page 548).
5. Open the fuser cover and hold the cover midway (approximately 30 degrees).6. Use you right hand to hold the left end of the fuser cover, and press its center from the inside. Use your
left hand to unhook the right side hinge pin (5) from the hinge hole on the rear tie plate (6) (Asm-Index:10-5, page 570).
7. Release the left side hinge pin (3) of the fuser cover from the hinge hole on the rear tie plate (6).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 401
Left Top CoverAsm-Index: 1-4, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).
12
2
hc2m958F
J131
Figure 26. Left Top Cover Removal
Chapter 6. Removal Procedures, Adjustments 402
3. Open the front tray assembly (Asm-Index: 5-1, page 557).
4. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572).
5. Remove the two screws (2) securing the left top cover to the printer frame.6. Lift up the back of the left top cover.7. Release the hook (3) from the front side cover (Asm-Index: 1-11, page 548) and remove the left top cover
from the printer body.
Attention: Support the left top cover to prevent damage to the console earth wire and the console harness.
8. Turn the left top cover to the left.9. Disconnect CN1 of the console harness (Asm-Index: 13-8, page 578) at the back of the console assembly
(Asm-Index: 1-18, page 548).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 403
Right Top CoverAsm-Index: 1-5, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
2
2
hc2m413f
1
Figure 27. Right Top Cover Removal
Chapter 6. Removal Procedures, Adjustments 404
3. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572)
4. Remove the two screws (2) securing the right top cover.5. Lift the cover away from the printer frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 405
Left Side Cover AssemblyAsm-Index: 1-6, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Loosen the two knurled screws (1) securing the left cover assembly (2).
1
6
FRONT
hc2m972f
17
7
6
8
8
3
5
2
4
Figure 28. Left Side Cover Removal
Chapter 6. Removal Procedures, Adjustments 406
3. Slide the cover backwards to remove its front edge from the front side cover (3) (Asm-Index: 1-11, page548), and remove the cover from the printer frame.
Replacement1. Insert the top edge of the cover (4) into the top slot (5).2. Line the three hooks (6) up with the three openings (7) in the printer frame.3. Slide the cover toward the front of the printer until the front tabs (8) fit into the grooves on the front side
cover (3).
Attention: Ensure that the top edge of the cover fits inside the lower edge of the left top cover.4. Secure the left cover assembly using two knurled screws.
Chapter 6. Removal Procedures, Adjustments 407
Left Lower CoverAsm-Index: 1-9, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left cover assembly (See page 406).
3. Remove the two screws (1) securing the left lower cover (2).4. Remove the cover from the printer frame.
1
1
2
hc2m415f
Figure 29. Left Lower Cover Removal
Chapter 6. Removal Procedures, Adjustments 408
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 409
Right Cover AssemblyAsm-Index: 1-10, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
1hc2m416f
3
3
3
2
Figure 30. Right Cover Assembly Removal
Chapter 6. Removal Procedures, Adjustments 410
3. Remove the right top cover (See page 404).
4. Remove the two screws (1) securing the bottom of the right cover assembly (2).5. Remove the three screws (3) securing the top and back of the cover.6. Remove the cover.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 411
Front Side CoverAsm-Index: 1-11, page 548.
2 hc2m417f
1
1
Figure 31. Front Side Cover Removal
Chapter 6. Removal Procedures, Adjustments 412
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Push down on the two hooks (1) at the upper end of the front side cover and move the top of the coveraway from the printer frame.
6. Lift up the cover slightly to clear the two hooks (2) at the bottom of the cover and remove the cover fromthe printer frame.
Replacement1. Hold the front side cover slightly tilting the upper side toward the front, and insert the hooks (2) on the
bottom end of the cover into the opening in the printer frame.2. Push down on the two hooks (1) at the upper end of the cover and insert them into the openings of the
printer frame.3. Replace the left cover assembly (See page 406).
4. Replace the left top cover (See page 402).
5. Close the fuser cover assembly (Asm-Index: 1-1, page 548).
Chapter 6. Removal Procedures, Adjustments 413
Exit CoverAsm-Index: 1-12, page 548.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
Note: Removing the fuser allows cables/wires to be re-routed on the cover wire retainer during replacement.
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Close the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572).
1 12
3
hc2m418f
Figure 32. Exit Cover Removal
Chapter 6. Removal Procedures, Adjustments 414
6. Remove the two screws (1) securing the exit cover (2).7. Tilt the exit cover toward the front so that the full stack actuator (3) (Asm-Index: 8-8, page 564) does not
touch the cover.
8. Lift the cover and remove it from the printer frame.
Replacement1. Lift the full stack actuator and hold it out of the way so that it will not touch the exit cover during step 2.2. Place the cover onto the printer frame.3. Secure the cover using two screws (silver, collared, 10mm).4. Open the Pop up/ROS assembly.5. Replace the right top cover (See page 404).
6. Replace the left top cover (See page 402).
7. Replace the fuser cover assembly (See page 402).
Chapter 6. Removal Procedures, Adjustments 415
Pop Up Cover AssemblyAsm-Index: 1-13, page 548.
RemovalSee Figure 33.
1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
12
2
3
3
hc2m419f
Figure 33. Pop Up Cover Assembly Removal
Chapter 6. Removal Procedures, Adjustments 416
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the exit cover (See page 414).
6. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572).
7. Remove the two screws (2) securing the pop up cover assembly.8. Close the Pop up/ROS assembly.9. Slide the pop up cover assembly slightly toward the front of the printer to disengage the hooks (3) at the
front and back of the cover.10. Lift the cover assembly and remove the cover from the pop up frame (Asm-Index: 11-1, page 572).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 417
Console AssemblyAsm-Index: 1-18, page 548.
JCN1
CN1
J131
2
1
hc2m41af
Figure 34. Console Assembly Removal
Chapter 6. Removal Procedures, Adjustments 418
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).
3. Remove the left top cover (See page 402) and the console assembly (2)(Asm-Index: 1-18, page 548).
4. Turn the left top cover (1) upside down.5. Release the tab at the bottom of the console assembly.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 419
Feeder PWBAsm-Index: 3-1, page 553.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550).
3. Remove the left top cover (See page 402).
4. Remove the left side cover assembly (See page 406).
2
4
1
3
3
FRONT
J203
J202J201
hc2m973f
Figure 35. Feeder PWB Removal
Chapter 6. Removal Procedures, Adjustments 420
5. Remove the left lower cover (See page 408).
6. Remove the front side cover (See page 412).
7. Remove the controller (See page 535).
8. Remove the four screws (3) securing the feeder PWB (4).
Note: To loosen the bottom left screw, insert the screwdriver through the opening in the printer frame.9. Remove the tray lower 1 harness (1) (Asm-Index: 3-2, page 553) from the harness clamp (2).
10. Remove the feeder PWB from the printer frame.11. Disconnect J201 of the tray harness (Asm-Index: 12-17, page 575), J202 of the tray lower 1 harness and
J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 421
Turn In ChuteAsm-Index: 3-4, page 553.
4
2
3
FRONT
hc2m974F
1
Figure 36. Turn In Chute Removal
Chapter 6. Removal Procedures, Adjustments 422
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550).
3. Hold open the turn chute assembly (Asm-Index: 3-5, page 553).
4. Flex the left side arm (1) of the turn in chute and remove its hinge hole from the pin (2) on the cassetteguide assembly left (Asm-Index: 3-6, page 553).
5. Remove the turn in chute (3) from the cassette guide (4).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 423
Turn Chute AssemblyAsm-Index: 3-5, page 553.
hc2m433F
2
21
Figure 37. Turn Chute Assembly Removal
Chapter 6. Removal Procedures, Adjustments 424
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the turn in chute (See page 422).
3. Hold the turn chute assembly (1) half open.4. Unhook the stoppers from the cassette guide left and right.5. Hold the chute assembly open and slide it to the left.6. Lift the rear of the printer and pull down the right side of the chute.7. Slide the chute to the right and remove it from the printer.8. Lower the printer.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 425
Cassette Guide Assembly LeftAsm-Index: 3-6, page 553.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
J206 J204
J203
hc2m434f
3 3
5
4
1
Figure 38. Cassette Guide Assembly Left Removal
Chapter 6. Removal Procedures, Adjustments 426
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the turn in chute (See page 422).
7. Remove the turn chute assembly (See page 424).
8. Remove the controller assembly (See page 535).
9. Remove the LVPS assembly (See page 521).
10. Disconnectv J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB (Asm-Index: 3-1, page
553),
v J204 from the feed solenoid (Asm-Index: 4-8, page 555), and
v J206 of the feeder harness from the electromagnetic clutch (Asm-Index: 4-9, page 555).
11. Release the electromagnetic clutch side of the feeder harness from the clamp.12. Remove the four screws (1) securing the cassette guide assembly left from outside of the frame.
13. Using a flat blade screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in,one by one, to release them from the printer frame.
14. Tilt the cassette guide (4), pulling its bottom edge from the inside of the printer frame (5).15. Ensure that the three upper hooks of the cassette guide are released from the printer frame.
Chapter 6. Removal Procedures, Adjustments 427
16. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator(Asm-Index: 3-16, page 553).
17. Push all harnesses on the cassette guide to free them from the printer frame.18. Remove the cassette guide from the printer frame.
Replacement1. Hold the cassette guide assembly left with the bottom to the right and the top to the left so that it will not
interfere with the cassette no paper actuator.2. Insert the cassette guide into the paper cassette well.3. Insert all connectors on the cassette guide through their openings in the printer frame.4. Place the upper three hooks of the cassette guide in their holes in the printer frame.5. Pull the harnesses to keep them from being pinched between the cassette guide and the printer frame.
Note: Adjust the position of cassette guide by sliding it to the front or rear so that the positioning pins onthe cassette guide enter into the openings in the printer frame.
6. Press on the bottom of the cassette guide to tilt it up until the upper and lower hooks lock into position.7. Secure the cassette guide from the outside of the printer frame using the four screws (1).8. Reconnect:v J203 to the feeder PWB,v J204 to the feed solenoid, andv J206 to the electromagnetic clutch.
9. Insert the electromagnetic clutch harness into the harness clamp.10. Replace the LVPS assembly (See page 521).
11. Replace the controller assembly (See page 535).
12. Replace the turn chute assembly (See page 424).
13. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 428
14. Replace the front side cover (See page 412).
15. Replace the left cover assembly (See page 406).
16. Replace the left top cover (See page 402).
17. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 429
Cassette No Paper SensorAsm-Index: 3-11, page 553.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550).
3. Open the fuser cover assembly (See page 400).
4. Remove the left top cover (See page 402).
1J205
hc2m435f
2
3
Figure 39. Cassette No Paper Sensor Removal
Chapter 6. Removal Procedures, Adjustments 430
5. Remove the left cover assembly (See page 406).
6. Remove the front side cover (See page 412).
7. Remove the controller assembly (See page 535).
8. Remove the turn in chute (See page 422).
9. Swing the arm of the cassette no paper actuator (1) (Asm-Index: 3-16, page 553) to the rear direction sothat the actuator is away from the cassette no paper sensor (2).
10. Open the turn chute assembly (Asm-Index: 3-5, page 553).
11. Using a small screwdriver, release the hooks (3) of the cassette no paper sensor from the cassette guideassembly left (Asm-Index: 11-30, page 572).
Attention: Do not move the cassette no paper sensor away. It is connected with the feeder harness.
12. Disconnect J205 from the sensor.13. Remove the sensor.
Replacement1. Swing up the arm of the cassette no paper actuator to the rear so that the actuator is away from the
cassette no paper sensor.2. Reconnect J205 to the cassette no paper sensor.3. Position the sensor in the opening of the cassette guide, and press the sensor into place until it snaps
into position.4. Put the extra length of the harness into the wiring channel of the cassette guide so that the harness does
not interfere with the gears.5. Replace the turn in chute (See page 422) and close the turn chute assembly.
6. Replace the controller assembly (See page 535).
7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 431
8. Replace the left cover assembly (See page 406).
9. Replace the left top cover (See page 402).
10. Replace the fuser cover assembly (See page 400).
11. Replace the paper cassette.
Chapter 6. Removal Procedures, Adjustments 432
Cassette Guide Assembly RightAsm-Index: 3-13, page 553.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the right top cover (See page 404).
4. Remove the right cover assembly (See page 410).
hc2m436f
2 4
1
13
3
Figure 40. Cassette Guide Assembly Right Removal
Chapter 6. Removal Procedures, Adjustments 433
5. Remove the front tray assembly (See page 455).
6. Remove the turn in chute (See page 422).
7. Remove the turn chute assembly (See page 424).
8. Remove the three screws (1) securing the cassette guide assembly right (2).9. Using a screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in, one by one,
to release them from the printer frame (4).10. Tilt the cassette guide, pulling its bottom edge from the inside of the printer frame.11. Ensure that three upper hooks of the cassette guide are released from the printer frame.12. Remove the cassette guide from the printer.
Chapter 6. Removal Procedures, Adjustments 434
Replacement1. Hold the cassette guide assembly right with the lower side to the left and the upper side to the right.2. Insert the cassette guide into the paper cassette well.3. Position the upper three hooks of the cassette guide in their respective holes.
Note: Adjust the position of the cassette guide by sliding it to the front or rear so that the positioning pinson the cassette guide enter into the openings in the printer frame.
4. Press the lower side of the cassette guide tilting it up until the upper and lower hooks are in position andthe lower hooks snap into place.
5. Secure the cassette guide using three screws (gold, self tapping, 8mm).6. Replace the turn chute assembly (See page 424).
7. Replace the turn in chute (See page 422).
8. Replace the front tray assembly (See page 455).
9. Replace the right cover assembly (See page 410).
10. Replace the right top cover (See page 404).
11. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 435
Cassette No Paper ActuatorAsm-Index: 3-16, page 553.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the left lower cover (See page 408).
2
hc2m437f
1
Figure 41. Cassette No Paper Actuator Removal
Chapter 6. Removal Procedures, Adjustments 436
6. Remove the front side cover (See page 412).
7. Remove the front tray assembly (See page 455).
8. Remove the turn in chute (See page 422).
9. Remove the turn chute assembly (See page 424).
10. Remove the controller assembly (See page 535).
11. Remove the LVPS assembly (See page 521).
12. Remove the cassette guide assembly left (See page 426).
13. Slide the shaft of the cassette no paper actuator (1) to the right (2).14. Release the left end of the actuator from the hole.15. Slide the actuator to the left and remove it from the printer frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 437
Feed RollAsm-Index: 4-1, page 555.
You may follow either procedure A or B.Note: The feed rollers are in the correct position for removal if power is switched off approximately 4 seconds
after initiating a print command.
hc2m441f
5
3
1
4
2
Figure 42. Feeder Roll Removal
Chapter 6. Removal Procedures, Adjustments 438
Procedure A Removal1. Install the paper cassette (Asm: 2, page 550) (with paper).
2. Open the turn chute assembly (Asm-Index: 3-5, page 553) and watch the paper path.
3. Run a test print and switch off the main switch when the front end of the paper touches the turn rollassembly (Asm-Index: 4-10, page 555).
4. Remove the paper cassette.5. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper
actuator (Asm-Index: 3-16, page 553) with your first, second and third fingers.
6. Press on the hook of the feed roll (1) to the front using your thumb to remove it.
Replacement1. Align the locating pin of the feed roll with the hole in the feed shaft.2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly.
Note: Ensure that the cams are located between the left and right pairs of the feed roll.3. Switch on the main power.4. Replace the paper cassette.
Procedure B Removal1. Remove the fuser cover assembly (See page 400).
2. Remove the left top cover (See page 402).
3. Remove the left cover assembly (See page 406).
4. Remove the front side cover (See page 412).
5. Remove the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 439
6. Remove the turn chute assembly (See page 424).
7. Remove the controller assembly (See page 535).
8. Press down on the armature of the feed solenoid (2) (Asm-Index: 4-8, page 555) to engage the feed gear(3) (Asm-Index: 4-5, page 555) with the feed idler gear (4) (Asm-Index: 4-15, page 555).
9. Rotate the rotor (5) of the main motor (Asm-Index: 10-6, page 570) clockwise until the rubber surface ofthe feed roll faces to the front.
Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls.
10. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paperactuator, with your first, second and third fingers.
11. Press on the hook of the feed roll to the front using your thumb to remove it.
ReplacementAttention: Do not damage the cassette no paper actuator and the rubber rolls.
1. Align the locating pin of the feed roll with the hole in the feed shaft.2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly.
Note: Ensure that the cams are located between the left and right pairs of the feed roll.3. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of
the feed roll (Asm-Index: 4-1, page 555) up until the feed gear (Asm-Index: 4-5, page 555) is releasedfrom the feed idler gear (Asm-Index: 4-15, page 555).
4. Replace the controller assembly (See page 535).
5. Replace the turn chute assembly (See page 424).
6. Replace the turn in chute (See page 422).
7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 440
8. Replace the left cover assembly (See page 406).
9. Replace the left top cover (See page 402).
10. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 441
Feed Shaft AssemblyAsm-Index: 4-2, page 555.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
hc2m442f
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8
1
4
2
5
67
Figure 43. Feeder Shaft Assembly Removal
Chapter 6. Removal Procedures, Adjustments 442
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the turn in chute (See page 422).
9. Remove the turn chute assembly (See page 424).
10. Remove the controller assembly (See page 535).
11. Remove the four feed rolls (See page 438).
12. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page555) and the feed solenoid (3) (Asm-Index: 4-8, page 555).
13. Remove the E-ring (4) that secures the feed gear to the feed shaft assembly (5).14. Hold down the armature of the feed solenoid and remove the feed gear together with the feed core
(Asm-Index: 4-3, page 555) and the feed core spring (Asm-Index: 4-4, page 555).
15. Remove the E-ring (6) that secures the right end the feed shaft assembly and remove the right side feedbearing (7) (Asm-Index: 4-6, page 555).
16. Slide the feed shaft to the left and remove the E-ring (8) that secures its left end.
Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls.
17. Position the cassette no paper actuator at the lower position.18. Slide the feed shaft to the right until its left end clears the printer frame.19. Pull the feed shaft to the lower left and release its right end from the printer frame, and remove the shaft
from the printer.
Chapter 6. Removal Procedures, Adjustments 443
ReplacementAttention: Do not damage the cassette no paper actuator and the rubber rolls.
1. Position the cassette no paper actuator in the lower position.2. Hold the feed shaft assembly with the flat side to the left.3. Hold the feed shaft, left end lowered and insert its right end into the right opening in the printer frame.4. Slide the feed shaft to the right and insert its left end to the feed bearing.5. Slide the feed shaft to the left and install an E-ring in the second groove from the left end. You may pull
out the right end of the shaft to ease the installation of the E-ring.6. Pressing the left end of the feed shaft to the right, insert the right side feed bearing into its opening in the
printer frame.7. Reinstall an E-ring to secure the right end of the feed shaft.8. Rotate the shaft and position the flat side up.9. Holding down the armature of the feed solenoid, install the feed gear together with the feed core and the
feed core spring.10. Secure the feed gear to the feed shaft using an E-ring.11. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) to the position that the larger holes on
the feed shaft can be seen from the back of the printer body.
12. Replace the four feed rolls (See page 438).
13. Reinstall the feed spring between the feed gear and the feed solenoid.14. Rotate the rotor of the main motor clockwise to place the rubber surface of the feed roll up until the feed
gear is released from the feed idler gear (Asm-Index: 4-15, page 555).
15. Replace the controller assembly (See page 535).
16. Replace the turn chute assembly (See page 424).
17. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 444
18. Replace the front side cover (See page 412).
19. Replace the right cover assembly (See page 410).
20. Replace the left cover assembly (See page 406).
21. Replace the right top cover (See page 404).
22. Replace the left top cover (See page 402).
23. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 445
Feed SolenoidAsm-Index: 4-8, page 555.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
J204
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4
2
5
1
Figure 44. Feed Solenoid Removal
Chapter 6. Removal Procedures, Adjustments 446
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555)and the feed solenoid (3).
8. Disconnect J204 of the feed solenoid (4) from the feeder harness (Asm-Index: 3-12, page 553) on thecassette guide assembly left (Asm-Index: 3-6, page 553).
9. Remove the screw (5) securing the feed solenoid to the cassette guide and remove the solenoid.
Chapter 6. Removal Procedures, Adjustments 447
Replacement1. Place the feed solenoid in position and secure it using a screw (silver, 6mm).2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly left.
Attention: Route the harness so that it does not touch the gears.3. Reinstall the feed spring between the feed gear and the feed solenoid.4. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of
the feed roll (Asm-Index: 4-1, page 555) up until the feed gear is released from the feed idler gear(Asm-Index: 4-15, page 555).
5. Press the armature of the feed solenoid and ensure the feed gear is released from the armature.6. Turn the feed gear clockwise and ensure the armature of the feed solenoid holds the feed gear.7. Replace the controller assembly (See page 535).
8. Replace the front side cover (See page 412).
9. Replace the left cover assembly (See page 406).
10. Replace the left top cover (See page 402).
11. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 448
Electromagnetic ClutchAsm-Index: 4-9, page 555.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
J206hc2m444f
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2
Figure 45. Electromagnetic Clutch Removal
Chapter 6. Removal Procedures, Adjustments 449
7. Disconnect J206 from the electromagnetic clutch (1).8. Remove the E-ring (2) securing the clutch.9. Remove the clutch from the turn roll assembly (Asm-Index: 4-10, page 555).
Replacement1. Place the electromagnetic clutch on the turn roll assembly and insert the notch on the clutch to the arm
over the printer frame.2. Secure the clutch using an E-ring.3. Reconnect P/J206 to the clutch.
Attention: Route the harness so that it does not touch the gears.4. Replace the controller assembly (See page 535).
5. Replace the front side cover (See page 412).
6. Replace the left cover assembly (See page 406).
7. Replace the left top cover (See page 402).
8. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 450
Turn Roll AssemblyAsm-Index: 4-10, page 555.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
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4
3
5
Figure 46. Turn In Roll Assembly Removal
Chapter 6. Removal Procedures, Adjustments 451
7. Remove the front side cover (See page 412).
8. Remove the turn in chute (See page 422).
9. Remove the turn chute assembly (See page 424).
10. Remove the controller assembly (See page 535).
11. Remove the electromagnetic clutch (See page 449).
12. Remove the left side E-ring (1) securing the turn gear (2) (Asm-Index: 4-12, page 555) and remove thegear from the turn roll assembly (3).
13. Remove the bearing from the turn roll assembly.14. Remove the right side E-ring (5) securing the right side turn bearing (6) and remove the bearing from the
turn roll assembly.15. Slide the turn roll assembly to the left, and remove its right end from the printer frame.16. Slide the right end of the turn roll assembly backward, and remove its left end from the printer frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 452
Rear Roll AssemblyAsm-Index: 4-11, page 555.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
5
1 2
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4
Figure 47. Rear Roll Assembly Removal
Chapter 6. Removal Procedures, Adjustments 453
7. Remove the front side cover (See page 412).
8. Remove the turn in chute (See page 422).
9. Remove the turn chute assembly (See page 424).
10. Remove the controller assembly (See page 535).
11. Remove the E-ring (1) securing the right side turn bearing (2) (Asm-Index: 4-13, page 555) and removethe bearing from the printer frame.
12. Remove the E-ring (3) securing the turn gear (4) (Asm-Index: 4-12, page 555) and remove the gear fromthe rear roll assembly (5).
13. Remove the left side turn bearing (6) from the rear roll assembly.14. Slide the rear roll assembly to the left, and remove its right end from the printer frame.15. Slide the right end of the rear roll assembly to the rear, and remove its left end from the printer frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 454
Front Tray Assembly and Front in TrayAsm-Index: 5-1 and 5-4, page 557.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
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2
3 1
Figure 48. Front Tray Assembly and Front In Tray Removal
Chapter 6. Removal Procedures, Adjustments 455
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the two screws (1) securing the front in tray (2).9. Open the front tray and pull out the front in tray together with the front tray assembly (3).
10. Flex the arm of the front in tray to release the hinge on the front tray assembly to separate the front intray and the front tray assembly.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 456
Auxiliary Tray Bracket AssemblyAsm-Index: 5-7, page 557.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the front tray assembly (Asm-Index: 5-1, page 557).
J137J222
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2
3
1
4
Figure 49. Auxiliary Tray Bracket Assembly Removal
Chapter 6. Removal Procedures, Adjustments 457
3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and keep it open during theoperation below.
4. Remove the EP cartridge (Asm-Index: 11-40, page 572).
5. Remove the two screws (1) securing the auxiliary tray bracket assembly (2) to the printer frame.6. Press down the front bottom tray (3) (Asm-Index: 5-5, page 557).
7. Slide the auxiliary tray bracket assembly slightly to the front to release the hooks on the printer framefrom the opening in the auxiliary tray bracket assembly.
8. Raise the right end of the auxiliary tray bracket and slide it slightly to the right.9. Release the left end of the auxiliary tray bracket from the printer frame without pulling the harnesses (4)
connected at the left rear of the auxiliary tray bracket.10. Disconnect J137 of the high harness assembly (Asm-Index: 6-5, page 559) and J222 of the toner relay
harness (Asm-Index: 12-18, page 575) from the auxiliary tray bracket.
11. Tilt the auxiliary tray bracket rear side up and remove it from the printer frame.
Replacement1. Open the front tray cover.2. Open the Pop up/ROS assembly and keep it open during the following steps.3. Press down the front bottom tray.4. Hold the auxiliary tray bracket assembly in one hand and hold the arm of the auxiliary tray no paper
actuator (Asm-Index: 5-10, page 557) in the up position using the other hand.
5. Tilt the auxiliary tray bracket rear side up and place the left end of the bracket slightly front from the finalposition holding the right end up.
6. Reconnect J137 and J222 and place the harnesses outside of the paper well area.
Note: You may need to remove the MCU PWB (See page 526 or 529) to reconnect J137 and J222. Afterreconnection, replace the MCU PWB.
Chapter 6. Removal Procedures, Adjustments 458
7. Hold the arm of the auxiliary tray no paper actuator up and place the auxiliary tray bracket in the printerframe.
Note: Ensure that the auxiliary tray no paper actuator fits into the hole in the front bottom tray.8. Secure the bracket to the printer frame using two screws (silver, 6mm).9. Replace the EP cartridge.
10. Close the Pop up/ROS assembly.11. Close the front tray assembly.
Chapter 6. Removal Procedures, Adjustments 459
Auxiliary Tray No Paper Sensor/ActuatorAsm-Index: 5-9 and 5-10, page 557.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the auxiliary tray bracket assembly (See page 457).
3. Remove the screw (1) securing the auxiliary tray actuator holder (2) to the auxiliary tray bracket assembly(Asm-Index: 5-7, page 557).
J134
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4
35
Figure 50. Auxiliary Tray No Paper Sensor/Actuator Removal
Chapter 6. Removal Procedures, Adjustments 460
4. Remove the actuator holder from the bracket with the no paper sensor (3) and the auxiliary tray no paperactuator (Asm-Index: 5-10, page 557) by lifting the right (sensor) end of the holder to disengage the hook(4) from the auxiliary tray bracket.
5. Disconnect J134 of the auxiliary tray no paper harness (Asm-Index: 5-12, page 557) from the auxiliary trayno paper sensor and remove the harness from the clamp on the auxiliary tray actuator holder (Asm-Index:5-11, page 557).
6. Holding the arm of the no paper actuator (5) up, squeeze the hooks of the no paper sensor, and removethe sensor from the holder.
7. Push the actuator end (as opposed to the sensor flag end) of the actuator (5) rearwards until it snaps outof the holder.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 461
Toner Sensor AssemblyAsm-Index: 5-13, page 557.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the EP cartridge (Asm-Index: 11-40, page 572).
J221
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2
3
Figure 51. Toner Sensor Assembly Removal
Chapter 6. Removal Procedures, Adjustments 462
3. To remove the entire assembly:a. Snap out the toner sensor holder (Asm-Index: 5-15, page 557).
b. Disconnect P/J922 at the left side of the printer.4. To remove just the toner sensor:
a. Using a small flat blade screwdriver, expand the hooks (1) on the upper side of the toner sensor holder(2) (Asm-Index: 5-15, page 557) to remove the toner sensor (3) (Asm-Index: 5-14, page 557) from theholder.
b. Disconnect J221 of the toner sensor harness (Asm-Index: 5-17, page 557) from the sensor.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 463
Front Bottom TrayAsm-Index: 5-5, page 557.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
hc2m456f
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1
2
3
Figure 52. Front Bottom Tray Removal
Chapter 6. Removal Procedures, Adjustments 464
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the exit cover (See page 414).
9. Remove the pop up cover assembly (See page 416).
10. Remove the front in tray together with the front tray assembly (See page 455).
11. Remove the auxiliary tray bracket assembly (See page 457).
12. Remove the BTR assembly (See page 466) to protect it from damage.
13. Remove the controller assembly (See page 535).
14. Remove the CRU guide assembly left (See page 506).
15. Remove the CRU guide assembly right (See page 510).
16. Lift the left side of the front bottom tray (1) and pull the tray out from under the cams (2) on the ends ofthe pick up roll assembly (Asm-Index: 6-8, page 559).
17. Lift the left front side of the tray and slide it to the left to remove.18. Remove the tray.19. Remove the auxiliary tray normal force springs (3) (Asm-Index: 5-6, page 557) if necessary.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 465
BTR AssemblyAsm-Index: 6-1, page 559.
hc2m461f
Figure 53. BTR Assembly Removal
Chapter 6. Removal Procedures, Adjustments 466
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the front tray assembly (Asm-Index: 5-1, page 557).
3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572). Ensure that it does not close duringthe operations below.
Attention: Do not touch the surface of the roll of the BTR assembly, the detack saw of the transport chuteassembly (Asm-Index: 6-2, page 559), or the window of the ROS assembly (Asm-Index: 11-20, page 572).
4. Turn up the levers of the BTR assembly (1) at both ends.5. Holding the levers, lift the BTR upwards at a 45 degree angle.6. Remove the BTR from the transport chute assembly.7. Place the BTR on a secure surface and cover the BTR with paper so as not to contaminate or damage it.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 467
Transport Chute AssemblyAsm-Index: 6-2, page 559.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
DTS
TR
J121
J13J124
J131P/J135
J14
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1
2
1
1
Figure 54. Transport Chute Assembly Removal (1)
Chapter 6. Removal Procedures, Adjustments 468
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the exit cover (See page 414).
9. Remove the pop up cover assembly (See page 416).
10. Remove the front in tray together with the front tray assembly (See page 455).
11. Remove the fuser assembly (See page 487).
12. Remove the controller assembly (See page 535).
13. Remove the Pop up/ROS assembly (See page 500).
14. Remove the auxiliary tray bracket assembly (See page 457).
15. Carefully remove the BTR assembly (See page 466).
16. Disconnect J180 of the fuser cover harness from the duplex interface PWB (Asm-Index: 12-6, page 575).
17. Remove the duplex interface PWB (See page 524).
18. Disconnect:a. J13 and J14 of the high harness assembly (Asm-Index: 6-5, page 559) from the MCU PWB.
b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector ofthe high harness assembly to the LVPS assembly (Asm-Index: 12-4, page 575) and to the interlockswitch (Asm-Index: 12-1, page 575).
c. J TR and J DTS of the high harness from the HVPS (Asm-Index: 12-11, page 575).
d. J131 from the registration clutch assembly (Asm-Index: 10-9, page 570).
e. J135 from the pick up solenoid (Asm-Index: 6-17, page 559).
Chapter 6. Removal Procedures, Adjustments 469
19. Release all harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page 559)from their clamps.
20. Remove the eight screws (1) securing the rear tie plate (2) (Asm-Index: 10-5, page 570).
21. Remove the rear tie plate from the printer body.22. Place the harnesses and wires to the side of the transport chute assembly.23. Remove the six screws securing the right CRU guide assembly (Asm-Index: 11-31, page 572).
24. Remove the six screws (3) securing the transport chute (4).25. Lift the transport chute and remove it from the printer frame.
Chapter 6. Removal Procedures, Adjustments 470
Replacement1. Place the transport chute assembly on the printer frame.
Attention: Ensure the front bottom tray (Asm-Index: 5-5, page 557) is located under the pick up roll assembly(Asm-Index: 6-8, page 559) and the pick up cams (Asm-Index: 6-12, page 559) presses down the front bottomtray.
2. Secure the transport chute assembly to the printer frame using six screws (silver, collared, 10mm).
hc2m463f
334
DTS
DTS
TR
TRJ14J14
J13
J13
J124
J124
Figure 55. Transport Chute Assembly Removal (2)
Chapter 6. Removal Procedures, Adjustments 471
3. Place the harnesses and wires to the side of the controller assembly (Asm-Index: 13-1, page 578).
4. Route all of the harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page559) under the clamps.
Attention: Route the harnesses so that they do not touch the gears.
5. Place the rear tie plate on the printer body and secure the tie plate using six screws (silver, 6mm) andtwo screws (gold, self tapping, 8mm).
6. Replace the MCU PWB together with the MCU holder (See page 529).
7. Reconnect:a. J13 and J14 of the high harness assembly to the MCU PWB.b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of
the high harness assembly to the LVPS assembly and to the interlock switch.c. J TR and J DTS of the high harness to the HVPS.d. J131 to the registration clutch assembly.e. J135 to the pick up solenoid.
8. Replace the duplex interface PWB (See page 524).
9. Reconnect P/J180 of the fuser cover harness to the duplex interface PWB.10. Replace the BTR assembly (See page 466).
11. Replace the auxiliary tray bracket assembly (See page 457).
12. Replace the Pop up/ROS assembly (See page 500).
13. Replace the controller assembly (See page 535).
14. Replace the fuser assembly (See page 487).
15. Replace the front in tray together with the front tray assembly (See page 455).
16. Replace the pop up cover assembly (See page 416).
17. Replace the exit cover (See page 414).
Chapter 6. Removal Procedures, Adjustments 472
18. Replace the front side cover (See page 412).
19. Replace the right cover assembly (See page 410).
20. Replace the left cover assembly (See page 406).
21. Replace the right top cover (See page 404).
22. Replace the left top cover (See page 402).
23. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 473
Pick Up RollAsm-Index: 6-9, page 559.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the auxiliary tray cover (Asm-Index: 5-2, page 557).
3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and ensure it does not close duringthe operations below.
hc2m465f
1
2
1
Figure 56. Pick Up Roll Removal
Chapter 6. Removal Procedures, Adjustments 474
4. Remove the EP cartridge (Asm-Index: 11-40, page 572).
5. Moe the auxiliary tray bracket assembly away from the rolls457), only diconnect the connectors ifnecessary.
6. If the rolls are not oriented as shown, you may need to rotate the shaft with the following procedure:a. Remove the controller assembly (See page 535).
b. Press on the armature of the pick up solenoid (Asm-Index: 6-17, page 559) down to engage the pickup gear (Asm-Index: 6-15, page 559) with the drive.
c. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up cams(Asm-Index: 6-12, page 559) are face down.
Note: Repeat steps 5 hrough 7 for right and left side rolls.
7. Release the hook on the core roll (1) (Asm-Index: 6-10, page 559) from the groove on the pick up shaft,using a flat blade screwdriver or finger nail. Slide the core roll away from the pick up roll (2).
8. Slide the pick up roll in the same direction as step 7 until it is clear of the drive pin on the pick up shaft.9. Remove the pick up roll from the shaft.
ReplacementNote: Repeat steps 1 through 3 for right and left side rolls.1. Holding the rubber side of the pick up roll up, place it on the pick up shaft on the outside of the drive pins
on the pick up shaft.
Attention: The arrows molded into the side of the pick up rolls show the direction of rotation. Be sure toinstall the rolls correctly.2. Slide the pick up roll inside inserting the drive pins on the pick up shaft into the grooves on the roll.3. Pressing down slightly on the retard pad assembly, (Asm-Index: 6-18, page 559), slide the core roll on the
same direction as step 2, until its hook snaps into the groove on the pick up shaft.
Chapter 6. Removal Procedures, Adjustments 475
4. Replace the auxiliary tray bracket assembly (See page 457).
5. Replace the EP cartridge.6. Close the Pop up/ROS assembly.
Chapter 6. Removal Procedures, Adjustments 476
Pick Up SolenoidAsm-Index: 6-17, page 559.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
P/J135hc2m466f
1
2
3
4
5 2
Figure 57. Pick Up Solenoid Removal
Chapter 6. Removal Procedures, Adjustments 477
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(Asm-Index: 12-6, page 575).
8. Remove the duplex interface PWB (See page 524).
9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575).
10. Remove the auxiliary tray bracket assembly (See page 457).
11. Press the armature (1) of the pick up solenoid (2) down.12. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up gear (3)
(Asm-Index: 6-15, page 559) stops.
13. Press down again on the armature of the pick up solenoid.14. Remove the pick up spring (4) (Asm-Index: 6-16, page 559) from the pick up gear and the housing of the
transport chute assembly (Asm-Index: 6-2, page 559).
15. Disconnect P/J135 from the harness for the pick up solenoid.16. Remove the screw (5) securing the solenoid on the transport chute through the opening in the left frame
assembly (Asm-Index: 10-11, page 570).
17. Remove the solenoid from the transport chute through the opening in the left frame.
Replacement1. Place the pick up solenoid in position on the transport chute assembly through the opening in the left
frame assembly so that the armature of the pick up solenoid meshes with the pick up gear.2. Secure the solenoid on the transport chute assembly through the opening in the left frame, using a screw
(gold, self tapping, 8mm).
Chapter 6. Removal Procedures, Adjustments 478
3. Reconnect P/J135 to the harness for the pick up solenoid and route the harness so that it does notinterfere with the gears.
4. Replace the pick up spring between the pick up gear and the housing of the transport chute assembly.5. Press the armature of the pick up solenoid down.6. Rotate the rotor of the main motor clockwise until the pick up gear stops (the rubber side of the pick up
rolls are face up).7. Replace the auxiliary tray bracket assembly (See page 457).
8. Replace the MCU PWB (See page 526) together with the MCU holder.
9. Replace the duplex interface PWB (See page 524).
10. Reconnect J180 to the duplex interface PWB11. Replace the controller assembly (See page 535).
12. Replace the front side cover (See page 412).
13. Replace the left cover assembly (See page 406).
14. Replace the left top cover (See page 402).
15. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 479
Retard Pad AssemblyAsm-Index: 6-18, page 559.
1
2 1hc2m467f
Figure 58. Retard Pad Assembly Removal (1)
Chapter 6. Removal Procedures, Adjustments 480
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the right top cover (See page 404).
4. Remove the right cover assembly (See page 410).
5. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and keep it open during theoperation below.
6. Remove the auxiliary tray bracket assembly (See page 457).
7. Remove the two pick up rolls (See page 474).
Apply the grease
3
4
5
5hc2m468f
Figure 59. Retard Pad Assembly Removal (2)
Chapter 6. Removal Procedures, Adjustments 481
8. Remove the three screws (1) securing the transport front chute (2) (Asm-Index: 6-7, page 559).
9. Release the hook on the center core roll (3) (Asm-Index: 6-10, page 559) and slide the center core roll tothe right away from the retard pad assembly (4).
Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft(Asm-Index: 6-13, page 559).
10. Press the retard pad assembly to the front and pull its rear side up to release the hooks on its rear sidefrom the transport chute assembly.
11. Hold the retard pad assembly at a right angle and ensure two retard springs (5) (Asm-Index: 6-19, page559) hang on it.
12. Remove the retard pad assembly together with the two retard springs by pressing to the front.13. Remove the retard springs from the retard pad assembly.
Replacement1. Open the Pop up/ROS assembly and keep it open during the operation below.
Note: Step 2 is applicable only when installing a new retard pad assembly.2. Using a small flat blade screwdriver apply the grease, packed with the retard pad assembly package, to
the bearing groove on the transport chute assembly.3. Reinstall the retard springs on the retard pad assembly.4. Hold the surface of the retard pad assembly at a right angle and place it in the hollow of the transport
chute assembly together with two retard springs.5. Position the retard springs in the groove in the hollow of the transport chute assembly using a small flat
blade screwdriver.6. Press the retard pad assembly to the front tilting its rear side to insert its rear side into the hollow on the
transport chute assembly until the retard pad assembly snaps in place.
Chapter 6. Removal Procedures, Adjustments 482
7. Slide the center core roll to the left until the hook on the core roll snaps in the groove on the pick upshaft.
Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft.8. Place the right side of the transport front chute on the transport chute aligning the position hole in the
front chute to the pin on the transport chute together with the grounding plate.9. Secure the transport front chute using three screws (silver, self tapping, with washer, 8mm).
10. Replace the two pick up rolls (See page 474).
11. Replace the auxiliary tray bracket assembly (See page 457).
12. Close the Pop up/ROS assembly.13. Replace the right cover assembly (See page 410).
14. Replace the right top cover (See page 404).
15. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 483
Registration Sensor/ActuatorAsm-Index: 7-7, page 562.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
7
8
31
1
526
5
4 P/J132
hc2m472f
10
9
Figure 60. Registration Sensor/Actuator Removal
Chapter 6. Removal Procedures, Adjustments 484
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the exit cover (See page 414).
9. Remove the fuser assembly (See page 487).
10. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it to keep it open withoutthe force of the pop up springs in the next step.
11. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers.
12. Close the Pop up/ROS assembly.13. Remove the controller assembly (See page 535).
14. Disconnect P/J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interfacePWB (Asm-Index: 12-6, page 575).
15. Remove the duplex interface PWB (See page 524).
16. Remove screws below:a. Two screws (1) securing the lower part of the back of the rear tie plate (2) to the base frame
assembly (Asm-Index: 10-2, page 570),
b. Two screws (3) securing the left of the tie plate to the left frame assembly (Asm-Index: 10-11, page570),
c. Two screws (4) securing the right of the tie plate to the right frame assembly (Asm-Index: 10-4, page570), and
d. Two screws (5) securing the upper part of the back of the tie plate to the transport chute assembly(Asm-Index: 6-2, page 559).
Chapter 6. Removal Procedures, Adjustments 485
17. Disconnect P/J132 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration sensor(Asm-Index: 7-6, page 562).
18. Remove the screw (6) securing the registration sensor bracket (7) (Asm-Index: 7-9, page 562) to thetransport chute assembly.
19. Remove the registration sensor bracket from the transport chute.20. Press down the arm of the registration actuator and squeeze the two hooks securing the sensor (8) to
the bracket to remove the registration sensor.21. Turn the registration actuator (9) to match the cutout on its left side shaft with the opening in the frame of
the registration sensor bracket.22. Release the left side shaft of the registration actuator from the bracket.23. Slide the actuator to the left and remove it from the bracket together with the registration spring (10).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 486
Fuser AssemblyAsm-Index: 8-1, page 564.
hc2m481f
4
5
3
2
1
Figure 61. Fuser Assembly Removal
Chapter 6. Removal Procedures, Adjustments 487
Removal
CAUTION:
<2-25> High temperature; switch off the printer and allow at least 20minutes for parts in this area to cool before handling. hc
sf02
25
1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover assembly (1) (Asm-Index: 1-1, page 548).
3. Loosen the two captured thumb screws (2) securing the fuser assembly (3) to the left frame assembly(Asm-Index: 10-11, page 570).
4. Lift up the fuser assembly (left end first), removing the locking tab (4) from the locking bracket (5).Removing the fuser assembly disconnects J142.
Replacement1. Place the fuser assembly on the top of the printer body, making sure J142 connects properly.2. Hold the tip of the full stack actuator (Asm-Index: 8-8, page 564) so that it does not interfere with the exit
cover (Asm-Index: 1-12, page 548).
3. Secure the fuser assembly to the left assembly using the two captured thumb screws.4. Close the fuser cover assembly.
Chapter 6. Removal Procedures, Adjustments 488
Main MotorAsm-Index: 10-6, page 570.
hc2m4a1f
1
2
2
J16
Figure 62. Main motor Removal
Chapter 6. Removal Procedures, Adjustments 489
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).
3. Remove the left cover assembly (See page 406).
4. Remove the front side cover (See page 412).
5. Remove the controller assembly (See page 535).
6. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(Asm-Index: 12-6, page 575).
7. Remove the duplex interface PWB (See page 524).
8. Disconnect J16 of the main motor (1) from the MCU PWB (Asm-Index: 12-8, page 575).
Attention: Move the main motor to keep from touching the MCU holder (Asm-Index: 12-9, page 575) duringsteps 9 and 10.
9. Remove the three screws (2) securing the main motor to the left frame assembly (Asm-Index: 10-11,page 570).
10. Remove the main motor from the left frame assembly.
ReplacementAttention: Move the main motor to keep from touching the MCU holder during the following step.
1. Place the main motor in the left frame assembly and secure the motor using three screws (silver, 6mm).2. Rotate the rotor of the main motor clockwise manually, and ensure it rotates smoothly.3. Reconnect J16 of the main motor to the MCU PWB.4. Replace the duplex interface PWB (See page 524).
5. Reconnect J180 of the fuser cover harness to the duplex interface PWB.
Chapter 6. Removal Procedures, Adjustments 490
6. Replace the controller assembly (See page 420).
7. Replace the front side cover (See page 412).
8. Replace the left cover assembly (See page 406).
9. Replace the left top cover (See page 402).
10. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 491
Paper Handling Gear AssemblyAsm-Index: 10-7, page 570.
J131
hc2m4a2f
2
3
2
2
1
Figure 63. Paper Handling Gear Assembly Removal
Chapter 6. Removal Procedures, Adjustments 492
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(Asm-Index: 12-6, page 575).
8. Remove the duplex interface PWB (See page 524).
9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575).
10. Disconnect J131 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration clutchassembly (Asm-Index: 10-9, page 570).
11. Unhook all the wires and harnesses from the clamp on the paper handling gear assembly (1).12. Remove the three screws (2) securing the paper handling gear assembly.13. Slightly pull out the gear assembly and release the registration clutch assembly from the drive bearing left
(3) (Asm-Index: 10-8, page 570).
14. Remove the gear assembly from the left frame assembly (Asm-Index: 10-11, page 570).
15. Remove the drive bearing left from the gear assembly.
Chapter 6. Removal Procedures, Adjustments 493
Replacement1. Place the drive bearing left in the paper handling gear assembly.2. Place the gear assembly in the left frame assembly inserting the shaft of the registration clutch assembly
into the drive bearing left.3. Secure the gear assembly to the left frame using three screws (silver, 6mm).4. Hook all the wires and harnesses to the clamp on the gear assembly.
Attention: Route the wires and harnesses to keep from touching the gears.5. Reconnect J131 of the high harness assembly to the registration clutch assembly.6. Replace the MCU PWB.7. Replace the duplex interface PWB (See page 524).
8. Reconnect J180 of the fuser cover harness to the duplex interface PWB (Asm-Index: 12-6, page 575).
9. Replace the controller assembly (See page 535).
10. Replace the front side cover (See page 412).
11. Replace the left cover assembly (See page 406).
12. Replace the left top cover (See page 402).
13. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 494
Registration Clutch AssemblyAsm-Index: 10-9, page 570.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
hc2m4a3f1
Figure 64. Registration Clutch Assembly Removal
Chapter 6. Removal Procedures, Adjustments 495
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(Asm-Index: 12-6, page 575).
8. Remove the duplex interface PWB (See page 524).
9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575).
10. Remove the paper handling gear assembly (See page 492) together with the drive bearing left(Asm-Index: 10-8, page 570).
11. Pull out the registration clutch assembly (1) and remove it from the left frame assembly (Asm-Index:10-11, page 570).
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 496
Main Gear AssemblyAsm-Index: 10-10, page 570.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
hc2m4a4f
1
2
Figure 65. Main Gear Assembly Removal
Chapter 6. Removal Procedures, Adjustments 497
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the exit cover (See page 414).
9. Remove the pop up cover assembly (See page 416).
10. Remove the front in tray (See page 455) including the front tray assembly (Asm-Index: 5-1, page 557).
11. Remove the BTR assembly (See page 466).
12. Remove the fuser assembly (See page 487).
13. Remove the controller assembly (See page 535).
14. Remove the duplex interface PWB (See page 524).
15. Remove the MCU PWB (See page 526) together with MCU holder (Asm-Index: 12-9, page 575).
16. Remove the main motor (See page 489).
17. Remove the paper handling gear assembly (See page 492) together with the drive bearing left(Asm-Index: 10-8, page 570).
18. Remove the registration clutch assembly (See page 495).
19. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) to a right angle and hold it in yourhand to keep from closing without the force of the pop up spring left/right (Asm-Index: 11-6 and 11-7,page 572) in the next step.
20. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers.
21. Close the Pop up/ROS assembly.22. Remove the eight screws securing the rear tie plate (Asm-Index: 10-5, page 570).
23. Remove the four screws (1) securing the main gear assembly (2) to the left frame assembly (Asm-Index:10-11, page 570).
Chapter 6. Removal Procedures, Adjustments 498
24. Slide the main gear assembly to the right and release gears and shafts from the frame. If you are havingtrouble removing the main gear assembly, remove the CRU guide assembly left (See page 506).
25. Pull the gear assembly up and behind to remove it from the frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 499
Pop Up UnitAsm-Index: 11-1 ∼11-23, page 572.
FRONT
J12 J17
hc2m977f
87
43
2
9
9
1
56
Figure 66. Pop Up Unit Removal (2)
Chapter 6. Removal Procedures, Adjustments 500
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the exit cover (See page 414).
7. Remove the pop up cover assembly (See page 416).
8. Remove the fuser assembly (See page 487).
9. Remove the controller assembly (See page 535).
10. Disconnect J12 of the ROS harness (Asm-Index: 12-16, page 575) and J17 of the CRU sensor assembly(Asm-Index: 11-15, page 572) from the MCU PWB (Asm-Index: 12-8, page 575).
11. Remove the ferrite core 1 (1) (Asm-Index: 12-21, page 575) from the harnesses using a small flat bladescrewdriver
12. Remove the screw (2) securing the pop up earth wire (3) (Asm-Index: 11-25, page 572) to the pop upframe (4) (Asm-Index: 11-1, page 572).
Note: The screw securing the other end of the pop up earth wire to the left frame assembly (Asm-Index:10-11, page 570) does not need to be removed.
13. Remove the screw (5) securing the clamp P (6) (Asm-Index: 12-22, page 575) to the left frame assemblyand release the ROS harness and the harness of the CRU sensor assembly
14. Release the ROS harness and the harness of the CRU sensor assembly from the opening in the leftframe.
Chapter 6. Removal Procedures, Adjustments 501
Attention: Do not touch the surface of the BTR assembly (Asm-Index: 6-1, page 559), the detack saw of thetransport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index:11-20, page 572) during the following step.
15. Open the Pop up/ROS assembly and hold it even, the spring force is released in next step.16. Release the pop up spring left (7) /right (8) (Asm-Index: 11-6 and 11-7, page 572) from the rear tie plate
(Asm-Index: 10-5, page 570).
17. Close the Pop up/ROS assembly.18. Remove the two screws (9) securing the pop up shaft (Asm-Index: 11-2, page 572) to the left frame
assembly and the right frame assembly (Asm-Index: 10-4, page 570) respectively.
19. Lift the Pop up/ROS assembly and slide it along the guide channel and remove the pop up unit from theprinter frame.
ReplacementReverse the Removal procedure.
Note: Ensure that the fuser guide lever is above the metal tab of the fuser drive gear as shown in Figure 66on page 500.
Chapter 6. Removal Procedures, Adjustments 502
CRU Sensor AssemblyAsm-Index: 11-15, page 572.
J17P/J171
hc2m4b3f
1
2
Figure 67. CRU Sensor Assembly Removal
Chapter 6. Removal Procedures, Adjustments 503
RemovalNote: If you can access the four mounting screws, you may be able to avoid complete removal of the Pop
up/ROS assembly.1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the front side cover (See page 412).
7. Remove the exit cover (See page 414).
8. Remove the pop up cover assembly (See page 416).
9. Remove the fuser assembly (See page 487).
10. Remove the controller assembly (See page 535).
11. Remove the Pop up/ROS assembly (See page 500).
12. Lay the Pop up/ROS assembly upside down.13. Release the harness of the CRU sensor assembly (1) from the clamp.14. Release the ROS harness (Asm-Index: 12-16, page 575) from the clamp, if necessary.
15. Remove the four screws (2) securing the CRU sensor assembly to the pop up frame (Asm-Index: 11-1,page 572) and remove the sensor assembly.
16. Disconnect P/J17 from the MCU.
Chapter 6. Removal Procedures, Adjustments 504
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 505
CRU Guide Assembly LeftAsm-Index: 11-30, page 572.
1
1
26
3 4
6
6
5
hc2m4b7f
Figure 68. CRU Guide Assembly Left Removal
Chapter 6. Removal Procedures, Adjustments 506
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).
9. Remove the controller assembly (See page 535).
10. Remove the center screw (1) of the HVPS (Asm-Index: 12-11, page 575) securing the HVPS to the CRUguide assembly left (2).
11. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during theoperation below.
12. Remove the two screws securing the left and right pop up latch feet (Asm-Index: 11-22, page 572) to theleft and right pop up latches (Asm-Index: 11-10 and 11-11, page 572).
13. Flex the left and right pop up latches and remove the left and right pop up latch feet.14. Open the Pop up/ROS assembly.
Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) or thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.
15. Remove the BTR assembly (See page 466) to protect it from damage.
Chapter 6. Removal Procedures, Adjustments 507
16. Remove the screw (3) securing the earth plate left (4) (Asm-Index: 11-32, page 572) on the top of theCRU guide assembly left.
17. Remove the screw (5) securing the upper part of the CRU guide assembly left.18. Remove the six screws (6) securing the CRU guide assembly.19. Press the pins on the left side of the left frame assembly (Asm-Index: 10-11, page 570) to release the
guide assembly.
20. Remove the guide assembly by carefully working it away from the printer frame.
Replacement1. Open the Pop up/ROS assembly and hold it open during the operation below.
Attention: Do not touch the detack saw of the transport chute assembly or the window of the ROS assemblyduring the following steps.
2. Place the CRU guide assembly left on the left frame assembly inserting the pins on the guide assemblyinto the openings in the printer frame.
3. Secure the guide assembly using six screws (silver, 8mm).4. Secure the upper part of the guide assembly using a screw (gold, 14mm).5. Secure the earth plate left using a screw (silver, 6mm)6. Replace the BTR assembly (See page 466).
7. Half close the Pop up/ROS assembly.8. Flex the pop up latch left/right and place the left and right pop up latch foot on the latch left/right. You
may rotate the latch foot to position it properly.9. Secure the left and right pop up latch foot to the pop up latch left/right using two screws (gold,
self-tapping, 10mm).10. Close the Pop up/ROS assembly.
Chapter 6. Removal Procedures, Adjustments 508
Attention: Ensure that the earth plate left contacts the pop up frame (Asm-Index: 11-1, page 572).
11. Secure the HVPS to the guide assembly using a screw (gold, self tapping, 8mm) on the center of theHVPS.
12. Replace the controller assembly (See page 535).
13. Replace the BTR assembly (See page 466).
14. Replace the front in tray (See page 455) together with the front tray assembly.
15. Replace the front side cover (See page 412).
16. Replace the right cover assembly (See page 410).
17. Replace the left cover assembly (See page 406).
18. Replace the right top cover (See page 404).
19. Replace the left top cover (See page 402).
20. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 509
CRU Guide Assembly RightAsm-Index: 11-31, page 572.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
hc2m4b8f
12
43
4 4
Figure 69. CRU Guide Assembly R Removal
Chapter 6. Removal Procedures, Adjustments 510
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).
9. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during theoperation below.
10. Remove the BTR assembly (See page 466) to protect from damage.
Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.
11. Remove the screw (1) securing the earth spring right (2) (Asm-Index: 11-33, page 572) to the CRU guideassembly right (3) and remove the spring.
12. Remove the five screws (4) securing the rear left end and front left side of the guide assembly.13. Press the pins on the right side of the right frame assembly (Asm-Index: 10-4, page 570) to release the
guide assembly.
14. Remove the guide assembly from the printer frame.
Replacement1. Open the Pop up/ROS assembly and hold it open during the operation below.
Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROSassembly during the following steps.
2. Place the guide assembly on the right frame assembly inserting pins on the guide assembly into theopenings.
Chapter 6. Removal Procedures, Adjustments 511
3. Secure the guide assembly using five screws (silver, 8mm).4. Secure the earth spring right to the guide assembly using a screw (gold, collared, 12mm).5. Replace the BTR assembly (See page 466).
6. Close the Pop up/ROS assembly.
Attention: Ensure that the earth spring right contacts the pop up frame (Asm-Index: 11-1, page 572).
7. Replace the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).
8. Replace the front side cover (See page 412).
9. Replace the right cover assembly (See page 410).
10. Replace the left cover assembly (See page 406).
11. Replace the right top cover (See page 404).
12. Replace the left top cover (See page 402).
13. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 512
Interlock SwitchAsm-Index: 12-1, page 575.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
J21J123
1 2
hc2m4c1f
Figure 70. Interlock switch Removal
Chapter 6. Removal Procedures, Adjustments 513
3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404).
5. Remove the left cover assembly (See page 406).
6. Remove the right cover assembly (See page 410).
7. Remove the front side cover (See page 412).
8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).
9. Remove the BTR assembly (See page 466) to protect it from damage.
10. Remove the controller assembly (See page 535).
11. Remove the CRU guide assembly left (See page 506).
12. Disconnect J123 of the interlock switch (1) from the LVPS assembly (Asm-Index: 12-4, page 575) andJ21 of the interlock switch on the MCU PWB (Asm-Index: 12-8, page 575) and release the harnessesfrom the clamps.
13. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during thefollowing steps.
Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.
14. Remove the screw (2) securing the interlock switch (Asm-Index: 12-1, page 575) to the left frameassembly (Asm-Index: 10-11, page 570).
15. Release the harness through the opening in the printer frame and remove the interlock switch from theframe.
Chapter 6. Removal Procedures, Adjustments 514
Replacement1. Open the Pop up/ROS assembly and hold it open during the operation below.
Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROSassembly during the following steps.
2. Insert the harness through the opening in the left frame assembly and place the interlock switch on theframe matching the position of the pin on the frame to the hollow on the switch.
3. Secure the interlock switch to the frame using a screw (gold, 12mm).
Attention: Ensure that the arm on the pop up frame presses the interlock switch when the Pop up/ROSassembly closes.
4. Reconnect J123 of the interlock switch to the LVPS and J21 of the interlock switch to the MCU PWB andattach the harnesses to the clamps.
5. Replace the CRU guide assembly left (See page 506).
6. Replace the controller assembly (See page 535).
7. Replace the BTR assembly (See page 466).
8. Replace the front in tray (See page 455) together with the front tray assembly.
9. Replace the front side cover (See page 412).
10. Replace the right cover assembly (See page 410).
11. Replace the left cover assembly (See page 406).
12. Replace the right top cover (See page 404).
13. Replace the left top cover (See page 402).
14. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 515
Fuser Cover SwitchAsm-Index: 12-2, page 575.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
hc2m4c2f
2
1
J190
12
J190
Figure 71. Fuser Cover switch Removal
Chapter 6. Removal Procedures, Adjustments 516
4. Remove the fan.5. Remove the fan duct.6. Using a flat-bladed screwdriver, squeeze the hooks securing the switch to the printer frame.7. Disconnect J190 of the fuser cover harness (Asm-Index: 12-13, page 575) from the fuser cover switch
(Asm-Index: 12-2, page 575) and remove the switch.
Replacement1. Press the cover switch up into the opening until the switch snaps into place.2. Reconnect J190 of the fuser cover harness to the fuser cover switch.3. Replace the fan duct.4. Replace the fan.5. Replace the left top cover (See page 402).
6. Replace the fuser cover assembly (See page 400).
Attention: Ensure that the fuser cover assembly (Asm-Index: 1-1, page 548) pushes the tab of the fusercover switch when the cover is closed.
Chapter 6. Removal Procedures, Adjustments 517
FanAsm-Index: 12-3, page 575.
J122
2
1
hc2m3c3f
Figure 72. fan Removal
Chapter 6. Removal Procedures, Adjustments 518
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect J122 of the fan (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and remove theferrite core1 (Asm-Index: 12-21, page 575) from the harness.
8. Release the harness of the fan from clamp and opening.9. Remove the two screws (2) securing the fan to the printer frame.
10. Remove the fan.
Replacement1. Place the fan in the printer frame so the label faces out, so that the air blows out.2. Secure the fan to the printer frame using two screws (silver, collared, 10mm).3. Reconnect J122 of the fan to the LVPS assembly and reinstall the ferrite core1 into the ROS harness
(Asm-Index: 12-16, page 575), the harness for the CRU sensor assembly (Asm-Index: 11-15, page 572),the fuser cover harness (Asm-Index: 12-13, page 575) and the harness to the fan.
4. Route the harness of the fan hanging to clamp and passing through opening so as not to interfere withgears and without slack.
5. Replace the controller assembly (See page 535).
6. Replace the front side cover (See page 412).
7. Replace the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 519
8. Replace the left top cover (See page 402).
9. Replace the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 520
LVPS AssemblyAsm-Index: 12-4, page 575.
6
3
1
4
5
2
8 9 10
7
7
J122 J127
J126
J123
J121
hc2m4C4F
Figure 73. LVPS Assembly Removal
Chapter 6. Removal Procedures, Adjustments 521
RemovalNote: The small fan shown in Figure 73 may not be on later versions of the printer.
1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).
3. Remove the left cover assembly (See page 406).
4. Remove the left lower cover (See page 408).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect all the connectors from the LVPS assembly.8. Release all the harnesses and the wire from their clamps.9. Remove the screw (1) securing the grounding wires to the printer frame.
Attention: Do not move the parts far, since the power inlet and the LVPS assembly (2) are connected bywires.10. Remove the three screws (3) securing the inlet holder (4) (Asm-Index: 12-5, page 575) to the left frame
assembly (Asm-Index: 10-11, page 570).
11. Remove the inlet holder from the printer frame together with the main power switch / power inlet (5).12. Remove the two screws (6) securing the main power switch / power inlet of the LVPS assembly (2) to the
inlet holder and remove the switch/inlet.13. Remove the four screws (7) securing the circuit board of the LVPS assembly.14. Carefully remove the LVPS from the printer frame by moving the LVPS slightly to the left and then lifting
and pivoting the bottom of the LVPS up to clear the printer frame.
Chapter 6. Removal Procedures, Adjustments 522
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 523
Duplex Interface PWBAsm-Index: 12-6, page 575.
J180
2
1hc2m4c5f
Figure 74. Duplex Interface PWB Removal
Chapter 6. Removal Procedures, Adjustments 524
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover.3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(1).
8. Remove the two screws (2) (silver, hexagon, 8mm) securing the rear end of the duplex interface PWB tothe left frame assembly (Asm-Index: 10-11, page 570).
9. Pull out the duplex interface PWB to the left to disconnect P/J18 from the MCU PWB (Asm-Index: 12-8,page 575).
10. Remove the duplex interface PWB.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 525
MCU PWB without MCU HolderAsm-Index: 12-8, page 575.
hc2m4c6f
2
4
3
1
Figure 75. MCU PWB Removal (1)
Chapter 6. Removal Procedures, Adjustments 526
RemovalNote: If possible, print a CONFIG page before replacing the MCU (see “Configuration Page” on page 250).
After replacing the MCU, the page count value will be reset to 0. This means that the true printer pagecount will be the value before MCU replacement plus the value shown on the CONFIG page afterreplacement.
1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).
3. Remove the left cover assembly (See page 406).
4. Remove the front side cover (See page 412).
5. Remove the controller assembly (See page 535).
6. Remove the duplex interface PWB (See page 524).
7. Disconnect all the connectors from the MCU PWB (1) (Asm-Index: 12-8, page 575).
8. Remove the four screws (2).9. Remove the MCU PWB.
Replacement1. Position the MCU PWB in the holder.2. Secure the MCU PWB to the frame using three screws.3. Secure two clamp Fs to the MCU PWB using a screw.4. Reconnect all the connectors to the MCU PWB.5. Route the harnesses to keep from touching the gears and edge of the frame.6. Replace the duplex interface PWB (See page 524).
7. Replace the controller assembly (See page 535).
Chapter 6. Removal Procedures, Adjustments 527
8. Replace the front side cover (See page 412).
9. Replace the left cover assembly (See page 406).
10. Replace the left top cover (See page 402).
Note: The next stes are applicable if you installed a new MCU PWB.
11. Reset the Toner and Fuser counters to 0 (see “Counters” on page 255).
12. See “S/N = 00-00000 (Serial Number)” on page 305 to update the serial number in the new MCU PWB.See Figure 5 on page 363 for the location of the serial number on the rear of the printer.
Chapter 6. Removal Procedures, Adjustments 528
MCU PWB with MCU HolderAsm-Index: 12-8 and 12-9, page 575.
hc2m4c7f
3
1
2
2
2
Figure 76. MCU PWB Removal (2)
Chapter 6. Removal Procedures, Adjustments 529
RemovalNote: If possible, print a CONFIG page before replacing the MCU (see “Configuration Page” on page 250).
After replacing the MCU, the page count value will be reset to 0. This means that the true printer pagecount will be the value before MCU replacement plus the value shown on the CONFIG page afterreplacement.
1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Remove the duplex interface PWB (See page 524).
Note: The models equipped with the controller inside the printer do not use the connectors P19 andP23. The models equipped with the controller outside of the printer do not use connector P23.
8. Disconnect all the connectors from the MCU PWB (1).9. Release all the harnesses from the clamp and the clamp Fs (Asm-Index: 12-23, page 575) on the MCU
holder.
10. Remove the four screws (2) securing the MCU holder (3) to the left frame assembly (Asm-Index: 10-11,page 570).
11. Remove the MCU PWB together with the MCU holder.
Chapter 6. Removal Procedures, Adjustments 530
Replacement1. Keeping the harness for P/J13 to the printer frame side from the MCU PWB, place the MCU PWB on the
left frame assembly together with the MCU holder.2. Secure the MCU holder to the frame using four screws (gold, 6mm).3. Reconnect all the connectors to the MCU PWB.4. Hook the harnesses to the clamp and the clamp Fs on the MCU holder.5. Route the harnesses to keep from touching the gears and edge of the frame.6. Replace the duplex interface PWB (See page 524).
7. Replace the controller assembly (See page 535).
8. Replace the front side cover (See page 412).
9. Replace the left cover assembly (See page 406).
10. Replace the left top cover (See page 402).
11. Replace the fuser cover assembly (See page 400).
Note: Steps 12 and 13 are applicable if you installed a new MCU PWB.
12. Set the NVRAM data according to the specification of the printer.13. Reset the Toner and Fuser counters to 0 (see “Counters” on page 255).
Chapter 6. Removal Procedures, Adjustments 531
HVPSAsm-Index: 12-11, page 575.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).
3. Remove the left cover assembly (See page 406).
DTS
TR
J151
hc2m4c8f
1
3
3
34
2
Figure 77. HVPS Removal
Chapter 6. Removal Procedures, Adjustments 532
4. Remove the front side cover (See page 412).
5. Remove the controller assembly (See page 535).
6. Disconnect all the connectors from the HVPS (1).
Attention: Do not touch the adjustment knob on the HVPS. Do not deform the spring plate on the CRU guideassembly left (Asm-Index: 11-30, page 572).
7. Remove the screw (2) securing the center of the HVPS to the CRU guide assembly left.8. Remove the four screws (3) securing the HVPS to the left frame assembly (Asm-Index: 10-11, page 570).
9. Remove the DTS and interlock cable holders from the front left frame.10. Holding the adjustment knob (4) (Asm-Index: 12-12, page 575) in your fingers, remove the HVPS from
the frame.
11. Remove the adjustment knob from the HVPS.
Replacement1. Place the adjustment knob on the HVPS.
Attention: Do not change the adjustments on the HVPS. Do not deform the spring attachment on the CRUguide assembly left.
2. Holding the volume knob in your fingers, place the HVPS in the left frame assembly.3. Secure the HVPS to the frame using four screws (6mm).
Attention: Ensure that the spring plate on the CRU guide assembly left touches the terminal on the HVPS.4. Secure the center of the HVPS to the CRU guide assembly left using a screw (gold, 8mm).5. Reconnect all the connectors to the HVPS.6. Route harnesses to keep from touching the gears and frame edges.7. Replace the controller assembly (See page 535).
Chapter 6. Removal Procedures, Adjustments 533
8. Replace the front side cover (See page 412).
9. Replace the left cover assembly (See page 406).
10. Replace the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 534
Controller AssemblyAsm-Index: 13-1, page 578.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).
4
Œ „ |Œ „ |
2
4hc2m4d1f
3
4
1
J31
J31
4
5
Figure 78. Controller Assembly Removal
Chapter 6. Removal Procedures, Adjustments 535
3. Remove the left cover assembly (See page 406).
4. Remove the front side cover (See page 412).
5. Disconnect J126 from the LVPS assembly (See Figure 73 on page 521).
6. Remove the three screws (2) securing the controller upper cover plate (3) (Asm-Index: 13-9, page 578) tothe printer frame.
7. Remove the six screws (4) securing the controller assembly to the left frame assembly (Asm-Index: 10-11,page 570).
8. Remove the controller assembly so that the controller harness (Asm-Index: 13-5, page 578) passes theopening in the frame.
Note: J31 is disconnected by removing the controller assembly from the left frame assembly.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 536
Controller PWBAsm-Index: 13-6, page 578.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402).
hc2m4d2f
3
3
2
4
15
5
Figure 79. Controller PWB Removal
Chapter 6. Removal Procedures, Adjustments 537
4. Remove the left cover assembly (See page 406).
5. Remove the front side cover (See page 412).
6. Remove the controller assembly (See page 535).
7. Remove the two screws (2) securing the external interface connector of the controller PWB.8. Remove the two screws (3) securing the rear panel (4) (Asm-Index: 13-3, page 578) to the left frame
assembly (Asm-Index: 10-11, page 570).
9. Remove the rear panel from the left frame assembly.10. Remove eleven screws (5) securing the controller PWB to the frame.11. Remove the controller PWB from the frame.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 538
Controller PWB SIMM
RemovalAttention: Follow the instructions for handling static-sensitive devices described on page 20.
1. Switch off printer power and unplug the power cord from the wall.2. Remove the left cover assembly (See page 406).
3. Locate the correct socket group for the type of SIMM you are installing. There are two socket groups: onecontains three sockets, the other contains four sockets. The DRAM SIMMs (memory) must are in one of
45°
hc2m133F
Flash memory,IPDS SIMMs
DRAM SIMMs
Notch
Notch
Figure 80. Controller PWB SIMM Removal
Chapter 6. Removal Procedures, Adjustments 539
the sockets in the socket group of three. The IPDS SIMM and the flash memory SIMMs (including theController SIMM with the operating system, PCL and PS) are in one of the sockets in the socket group offour.SIMMs should be loaded from the left to the right but the position of the SIMM within the group of socketsdoes not matter.
4. Using your thumbs, press with even pressure on both ends of the clips until the SIMM is released. Pivotthe SIMM 45 degrees and remove it from the socket.
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 540
Network Interface Card
RemovalAttention: Follow the instructions for handling static-sensitive devices described on page 20.
1. Switch off printer power and unplug the power cord from the wall.2. Move to the back of the printer. Two slots for interface cards are located at the right side of the back of the
printer.3. Loosen and remove the thumbscrews that hold the network interface cards.4. Slide the card from the slot guides, pulling slowly, and remove it from the printer.
hc2m134F
Figure 81. Network Interface Card Removal
Chapter 6. Removal Procedures, Adjustments 541
ReplacementReverse the Removal procedure.
Chapter 6. Removal Procedures, Adjustments 542
Chapter 7. Preventive Maintenance and Usage KitPreventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543Usage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543Reconditioning Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
Preventive MaintenanceThere is no preventive maintenance for the IBM InfoPrint 20.
Usage KitThe parts included in this kit should all be replaced approximately every 200K prints. The failure of these partscan impair printer performance. The customer is responsible for replacing the Usage Kit.
See “Appendix B. Supplies” on page 591 for ordering information and part numbers.
See the “IBM InfoPrint 20: User’s Guide” for replacement instructions.
Reconditioning KitThere is no reconditioning kit for the IBM InfoPrint 20.
© Copyright IBM Corp. 1998 543
Chapter 8. Parts CatalogHow to Use the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
Assembly-Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547
Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548Assembly 2: Paper Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550Assembly 3: Paper Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .553Assembly 4: Paper Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555Assembly 5: Multi-Sheet Inserter (Auxiliary Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557Assembly 6: Paper Transportation I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559Assembly 7: Paper Transportation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562Assembly 8: Fuser and Paper Exit I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .564Assembly 9: Fuser and Paper Exit II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567Assembly 10: Fuser and Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570Assembly 11: Pop Up and Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572Assembly 12: Electrical I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575Assembly 13: Electrical II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578Assembly 99: Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580Assembly 100: Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .585
Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587Commonly Used Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587Commonly Used Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
© Copyright IBM Corp. 1998 544
Cleaners and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
Chapter 8. Parts Catalog 545
How to Use the Parts CatalogThe parts catalog illustrations and tables show and list all parts of the associated assembly. Below is anexample of these tables with an explanation.
Asm–Index Grid
PartNumber Units Description
1– NP Cover asm.
–1 B2 90H0000 1 v Cover, delivery
–2 C1 90H0001 1 v Hinge, stopper (with 1-3 and 1-4)
–3 C2 NP 1 v v Guide, left
–4 C1 NP 1 v v Cover, block, front
Assembly-IndexAll parts of assembly number 1 are listed in this column. The numbers 1, 2, 3, and 4, and so forth refer tothe corresponding numbers in the illustration for this assembly.
Index number 2, part number 90H0001, is a subassembly of assembly 1. Notice that index number 2includes two parts, 3 and 4. These parts cannot be ordered individually. If one is needed, order thesubassembly, index number 2.
GridEach parts illustration is divided into grids. The grids are labeled A, B, C, and D vertically and 1, 2, and 3horizontally. The combination of a vertical grid (such as C) and a horizontal grid (such as 1) provides thecoordinates C1. The index number of the part will be located in the C1 area.
Chapter 8. Parts Catalog 546
Part NumberThis is the IBM part number. NP (non procurable) means the part or assembly cannot be ordered.
UnitsThe number in this column represents the number of usages of that part in this assembly.
DescriptionThis is a description of the assembly or part.
Chapter 8. Parts Catalog 547
Assembly Locations
Assembly 1: Covers
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m301F
Chapter 8. Parts Catalog 548
Table 66. Assembly 1: Covers
Asm–Index Grid
PartNumber Units Description
1– Covers
–2 A3 90H0754 1 Fuser cover
–3 A3 90H0755 1 Fuser cap cover
–4 A2 90H3329 1 Left top cover
–5 B4 90H3383 1 Right top cover
–6 B1 07L0038 1 Left cover assembly (with 1-7, 1-8)
–7 B1 NP 1 v Left side cover
–8 B2 NP 1 v Controller shield
–9 C1 90H0759 1 Left lower cover
–10 C4 90H0760 1 Right cover assembly
–11 C1 90H0761 1 Front side cover
–12 B4 90H0762 1 Exit cover
–14 A2 90H0763 1 Pop up upper cover
–15 B2 90H0764 1 Pop up lower cover
–16 A2 90H0765 1 Exit extent tray
–17 A2 90H0766 1 Tray stopper
–18 A1 90H3466 1 Console assembly and Overlay
–19 A1 90H0768 1 Console ground wire (Early models only)
Asm–Index numbers not used: 1, 13
Chapter 8. Parts Catalog 549
Assembly 2: Paper Cassette
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m302F1 (with 2-24)
Chapter 8. Parts Catalog 550
Table 67. Assembly 2: Paper Cassette
Asm–Index Grid
PartNumber Units Description
2– Paper cassette
–1 C1 90H0719 1 A3 Long cassette assembly (with 2-2∼2-24)
–1 C1 90H0718 1 A4 Short cassette assembly (with 2-2∼2-24)
–2 B3 NP 1 v Cassette housing
–3 C4 NP 1 v Cassette bottom cover
–4 A2 NP 1 v Side guide grip
–5 A3 NP 2 v Snubber guide
–6 A2 NP 1 v Side guide assembly L
–7 A3 NP 1 v Side guide assembly R
–8 C2, C3 NP 2 v Rack gear
–9 C3 NP 1 v Pinion gear
–10 A1 NP 1 v Bottom plate assembly
–11 A1 NP 1 v Normal force spring plate
–12 A1, A2 NP 2 v Cassette side normal force spring
–13 B1 NP 1 v Cassette normal force spring
–14 B2 NP 1 v End guide plate
–15 A2 NP 1 v Paper end guide
–16 A2 NP 1 v End guide spring
–17 A2 NP 1 v End guide
–18 C2 NP 1 v Pivot plate
Chapter 8. Parts Catalog 551
Table 67. Assembly 2: Paper Cassette (continued)
Asm–Index Grid
PartNumber Units Description
2– Paper cassette
–19 C2 NP 1 v Sector gear
–20 B1 NP 1 v Size cam
–21 B2 NP 1 v Locking pin
–22 B1 NP 1 v Cassette latch L
–23 C3 NP 1 v Cassette latch R
–24 B1, B3 NP 2 v Cassette latch spring
–25 C1 90H0770 1 A3 Cassette cover
–25 C1 90H3467 1 A4 Cassette cover
Chapter 8. Parts Catalog 552
Assembly 3: Paper Feeder I
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m303F
6 (with 7-12, 18)
Chapter 8. Parts Catalog 553
Table 68. Assembly 3: Paper Feeder I
Asm–Index Grid
PartNumber Units Description
3– Paper Feeder
–1 A4 90H0771 1 Feeder PWB
–2 B4 90H0772 1 Feeder harness (Tray Lower)
–4 C2 90H0773 1 Turn in chute
–5 C2 90H0774 1 Turn chute assembly
–6 B3 90H0775 1 Cassette guide assembly left (with 3-7∼3-12, 3-18)
–7 B4 NP 1 v Cassette guide L
–8 C4 NP 4 v Size actuator
–9 B4 NP 1 v Size actuator spring
–10 B3 NP 1 v Low paper actuator
–11 C3 90H0776 1 v MSI/Cassette no paper sensor
–12 C4 NP 1 v Feeder harness
–18 C3 NP 1 v Cassette guide cap
–13 B1 90H0777 1 Cassette guide assembly right (with 3-14, 3-15)
–14 B2 NP 1 v Cassette guide R
–15 B2 NP 1 v Cassette stopper spring
–16 B2 90H0778 1 Cassette no paper actuator
Asm–Index numbers not used: 3, 17
Chapter 8. Parts Catalog 554
Assembly 4: Paper Feeder II
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m304F
Chapter 8. Parts Catalog 555
Table 69. Assembly 4: Paper Feeder II
Asm–Index Grid
PartNumber Units Description
4– Paper feeder II
–1 C2 4 Feed roll (in kit P/N 90H0779) (see page 580)
–2 C2 90H0780 1 Feed shaft assembly
–3 B4 1 Feed core (in kit P/N 90H0781) (see page 580)
–4 B4 1 Feed core spring (in kit P/N 90H0781) (see page 580)
–5 B4 1 Feed gear (in kit P/N 90H0781) (see page 580)
–6 A3, B1 2 Feed bearing (in kit P/N 06L9997) (see page 580)
–7 B4 1 Feed spring (in kit P/N 90H0781) (see page 580)
–8 A4 90H0782 1 Feed solenoid
–9 B4 90H0783 1 Electromagnetic clutch
–10 C2 90H0784 1 Turn roll assembly
–11 C2 90H0785 1 Rear roll assembly
–12 B4 2 Turn gear (in kit P/N 90H3384) (see page 580)
–13 A1, B1,B3, B4
90H0786 4 Turn bearing
–14 B3 1 Turn idler gear (in kit P/N 90H3384) (see page 580)
–15 B4 1 Feed idler gear (in kit P/N 90H3384) (see page 580)
–16 C4 2 Out idler gear (in kit P/N 90H3384) (see page 580)
Chapter 8. Parts Catalog 556
Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)
7 (with 8-17)
13 (with 14-17)
hc2m305F
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Chapter 8. Parts Catalog 557
Table 70. Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)
Asm–Index Grid
PartNumber Units Description
5– Multi-Sheet Inserter
–1 C2 90H0790 1 Front tray assembly (with 5-2, 5-3)
–2 C2 NP 1 v Front tray cover
–3 C2 NP 1 v Front extent tray
–4 C3 90H0791 1 Front in tray
–5 A1 90H0792 1 Front bottom tray
–6 A3 2 Normal force spring (in kit P/N 90H3380) (see page 580)
–7 B4 90H0793 1 MSI Bracket assembly (with 5-8∼5-17)
–8 B4 NP 1 v Sensor bracket
–9 A4 90H0776 1 v MSI No paper sensor (same as 3-11)
–10 A4 90H0794 1 v MSI No paper actuator
–11 A4 NP 1 v MSI actuator holder
–12 A4 NP 1 v MSI no paper harness
–13 A3 90H0795 1 v Toner sensor assembly (with 5-14∼5-17)
–14 A3 NP 1 v v Toner sensor
–15 A3 NP 1 v v Toner sensor holder
–16 A3 NP 1 v v Toner sensor spring
–17 A3 NP 1 v v Toner sensor harness
Chapter 8. Parts Catalog 558
Assembly 6: Paper Transportation I
1 2 3 4
1 2 3 4
A
B
C
A
B
C
8 (with 9-13)
2 (with 3-19)
hc2m306F
Chapter 8. Parts Catalog 559
Table 71. Assembly 6: Paper Transportation I
Asm–Index Grid
PartNumber Units Description
6– Paper transportation I
–1 A2 90H0796 1 BTR assembly (Supply Item - Included in Usage Kit)
–2 A3 90H0797 1 Transport chute assembly 100/110V (with 6-3∼6-19)
–2 A3 90H3421 1 Transport chute assembly 220V (with 6-3∼6-19)
–3 B4 NP 1 v Transport sub assembly (same as 7-1)
–4 A4 NP 1 v Connector bracket2
–5 A4 11L5354 1 v High harness assembly (100V/110V)
–5 A4 11L6539 1 v High harness assembly (220V)
–6 A3 NP 1 v Transport out plate
–7 B2 NP 1 v Transport front chute
–8 C3 NP 1 v Pick up roll assembly (with 6-9∼6-13)
–9 C3 90H0798 2 v v Pick up roll
–10 C2, C3,C4
NP 3 v v Core roll
–12 C2, D4 NP 2 v v Pick up cam
–13 C3 NP 1 v v Pick up shaft
–14 C4 NP 1 v Transport bearing
–15 C2 1 v Pick up gear (in kit P/N 90H3384) (see page 580)
–16 C2 1 v Pick up spring (in kit P/N 90H3380) (see page 580)
–17 B2 90H0799 1 v Pick up solenoid
Chapter 8. Parts Catalog 560
Table 71. Assembly 6: Paper Transportation I (continued)
Asm–Index Grid
PartNumber Units Description
6– Paper transportation I
–18 B2 1 v Retard pad (in kit P/N 90H0800) (see page 580)
–19 B3 2 v Retard pad spring (in kit P/N 90H0800) (see page 580)
Asm–Index numbers not used: 11
Chapter 8. Parts Catalog 561
Assembly 7: Paper Transportation II
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m307F
1 (with 2-19)
Chapter 8. Parts Catalog 562
Table 72. Assembly 7: Paper Transportation II
Asm–Index Grid
PartNumber Units Description
7– Paper transportation II
–1 B2 NP 1 Transport sub assembly (with 7-2∼7-19) (same as 6-3)
–2 B3 NP 1 v Transport housing assembly
–3 A2, A4 11L5337 2 v BTR bearing
–4 A2 1 v BTR spring left (in kit P/N 90H3380) (see page 580)
–5 A4 1 v BTR spring right (in kit P/N 90H3380) (see page 580)
–6 A2 1 v Registration sensor (in kit P/N 90H3290) (see page 580)
–7 A2 1 v Registration actuator (in kit P/N 90H3290) (see page 580)
–8 A3 1 v Registration spring (in kit P/N 90H3290) (see page 580)
–9 A3 1 v Registration sensor bracket (in kit P/N 90H3290) (see page 580)
–10 C2 90H3291 1 v Metal registration roll
–11 B2 90H3292 1 v Rubber registration roll
–12 B1 1 v Registration in gear (in kit P/N 90H3384) (see page 580)
–13 C3 1 v Registration back gear (in kit P/N 90H3384) (see page 580)
–14 C3 1 v Registration front gear (in kit P/N 90H3384) (see page 580)
–15 B1, C3 2 v Registration front bearing (in kit P/N 06L9997) (see page 580)
–16 B1, B3 2 v Registration back bearing (in kit P/N 06L9997) (see page 580)
–17 B2 07L0044 1 v Registration spring left
–18 B3 07L0044 1 v Registration spring right
–19 C2 90H3293 1 v Rear chute assembly
Chapter 8. Parts Catalog 563
Assembly 8: Fuser and Paper Exit I
26
hc2m308F
28
2 7
1 (with 2-28)
10 (with 11-14)
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Chapter 8. Parts Catalog 564
Table 73. Assembly 8: Fuser and paper exit I
Asm–Index Grid
PartNumber Units Description
8– Fuser and paper exit
–1 A3 90H3465 1 Fuser sub-assembly 100V (with 8-2∼8-28, including BTR Assembly 90H0796)Supply
–1 A3 90H0750 1 Fuser sub-assembly 110V (with 8-2∼8-28, including BTR Assembly 90H0796)Supply
–1 A3 90H0751 1 Fuser sub-assembly 220V (with 8-2∼8-28, including BTR Assembly 90H0796)Supply
–2 C3 NP 1 v Fuser sub assembly (same as 9-1)
–3 B2 NP 1 v Fuser cover L
–4 C4 NP 1 v Fuser cover R
–5 A1 NP 1 v Fuser label assembly
–6 A1 NP 1 v Fuser top cover assembly
–7 A2 NP 1 v Full stack sensor
–8 A2 NP 1 v Full stack actuator
–9 A2 1 v Full stack spring (in kit P/N 90H3380) (see page 580)
–10 A3 NP 1 v Fuser rear assembly (with 8-11∼8-14)
–11 A3 NP 1 v v Fuser rear cover
–12 A2 NP 1 v v Exit eliminator
–13 B2 NP 1 v v Eliminator plate L
–14 B2 NP 1 v v Eliminator plate R
–15 B2 NP 1 v Exchange chute
Chapter 8. Parts Catalog 565
Table 73. Assembly 8: Fuser and paper exit I (continued)
Asm–Index Grid
PartNumber Units Description
8– Fuser and paper exit
–16 B3 NP 1 v Exchange lever
–17 B3 NP 1 v Exchange spring
–18 C4 NP 1 v Exit chute
–19 C4 NP 1 v Finger bracket
–20 B3, B4 NP 6 v Size cam
–21 B3, B4 NP 6 v Heat roll finger
–22 B4 NP 6 v Exit chute roll
–23 B4 NP 1 v Exit torsion spring
–24 B4 NP 1 v Exit actuator
–25 C2 NP 1 v Exit sensor
–26 C2 NP 1 v Exit sensor clip
–27 B2 NP 1 v Clip
–28 A3 NP 1 v Cover
Chapter 8. Parts Catalog 566
Assembly 9: Fuser and Paper Exit II
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m309F
1 (with 2-34)
Chapter 8. Parts Catalog 567
Table 74. Assembly 9: Fuser and Paper Exit II
Asm–Index Grid
PartNumber Units Description
9– Fuser and Paper Exit II
–1 A4 NP 1 Fuser sub assembly (with 9-2∼9-34) (same as 8-2)
–2 C3 NP 1 v Fuser frame assembly
–3 A2 NP 1 v Connector bracket1
–4 A1 NP 1 v Fuser harness
–5 A2 NP 1 v Heater assembly
–6 C3 NP 1 v Lamp guide
–7 B3 NP 1 v Thermal fuse
–8 B2 NP 1 v Thermostat
–9 B3 NP 1 v Temperature sensor assembly
–10 A2 NP 1 v Heat roll
–11 B1, C3 NP 1 v Heat roll ring
–12 B1 NP 1 v Heat roll bearing L
–13 C3 NP 1 v Heat roll bearing R
–14 C3 NP 1 v Heat roll diode
–15 A4 NP 1 v Pressure roll
–16 A3, A4 NP 2 v Pressure roll bearing
–17 A3, A4 NP 2 v Nip spring
–18 A3 NP 1 v Nip lever L
–19 A4 NP 1 v Nip lever R
Chapter 8. Parts Catalog 568
Table 74. Assembly 9: Fuser and Paper Exit II (continued)
Asm–Index Grid
PartNumber Units Description
9– Fuser and Paper Exit II
–20 C1 NP 1 v Pressure roll eliminator
–21 B3 NP 1 v Pressure roll earth plate
–22 C2 NP 1 v Fuser inlet chute
–23 C1 NP 1 v Heat roll idler gear
–24 C1 NP 1 v Heat roll idler flange
–25 B1 NP 1 v Heat roll idler shaft
–26 B1 NP 1 v Heat roll gear
–27 B1 NP 1 v Exit idler gear
–28 B1 NP 1 v Exit idler shaft
–29 B1 NP 1 v Exit gear
–30 B1 NP 1 v Exit bearing
–31 C1 NP 1 v Exit roll assembly
–32 B3 NP 1 v STS plate
–33 B3 NP 2 v Pad
–34 B2 NP 1 v Clip
Chapter 8. Parts Catalog 569
Assembly 10: Fuser and Drive
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m310F
Chapter 8. Parts Catalog 570
Table 75. Assembly 10: Fuser and Drive
Asm–Index Grid
PartNumber Units Description
10– Fuser and drive
–2 C2 NP 1 Base frame assembly
–4 A1 NP 1 Right frame assembly
–5 A2 NP 1 Rear tie plate
–6 A4 90H3294 1 Main motor
–7 A4 90H3295 1 Paper handling gear assembly
–8 A4 NP 1 Drive bearing L
–9 A4 90H3296 1 Registration clutch assembly
–10 A3 90H3297 1 Main gear assembly
–11 C4 NP 1 Left frame sub assembly
–12 C4 NP 1 Frame bottom plate
Asm–Index numbers not used: 1, 3
Chapter 8. Parts Catalog 571
Assembly 11: Pop Up and Xerographics
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m311F
20A
20 (with 1-23)
Chapter 8. Parts Catalog 572
Table 76. Assembly 11: Pop Up and Xerographics
Asm–Index Grid
PartNumber Units Description
11– Pop Up and Xerographics
–20 A3 90H3304 1 Pop Up/ROS assembly (with 11–1∼11–23)
–1 A1 NP 1 v Pop up frame
–2 A3 NP 1 v Pop up shaft
–3 A1 90H3298 1 v Fuser guide lever
–4 A2 NP 1 v Pop up bearing L
–5 A2 NP 1 v Pop up bearing R
–6 A2 1 v Pop up spring, left (in kit P/N 90H3380) (see page 580)
–7 A3 1 v Pop up spring, right (in kit P/N 90H3380) (see page 580)
–8 B1 90H3299 1 v Latch lever
–9 A1 NP 1 v Latch shaft
–10 A1 90H3300 1 v Pop up latch, left
–11 B2 90H3301 1 v Pop up latch, right
–12 A1, B2 2 v Pop up latch spring (in kit P/N 90H3380) (see page 580)
–13 A1, A2 NP 2 v CRU latch
–14 A1, A2 2 v CRU latch spring (in kit P/N 90H3380) (see page 580)
–15 B1 90H3302 1 v CRU sensor assembly
–16 A1, A2 NP 2 v ROS spring holder
–17 B1, B2 2 v ROS push spring (in kit P/N 90H3380) (see page 580)
–18 B1 NP 1 v ROS support
Chapter 8. Parts Catalog 573
Table 76. Assembly 11: Pop Up and Xerographics (continued)
Asm–Index Grid
PartNumber Units Description
11– Pop Up and Xerographics
–19 B1 90H3303 1 v Interlock actuator
–20A C1 NP 1 v ROS assembly
–21 A1 NP 1 v Guide arm
–22 B1, B2 90H3305 2 v Pop up latch foot
–23 A2 NP 3 v Pop up clamp
–24 A2 NP 1 Shaft earth wire
–25 A1 NP 1 Pop up earth wire
–26 A2 NP 1 ROS spacer
–30 A4 90H3306 1 CRU guide assembly, left
–31 A4 90H3307 1 CRU guide assembly, right
–32 B3 NP 1 Earth plate L
–33 A4 NP 1 Earth spring R
–40 C2 90H0748 1 EP (Toner) cartridge (Supply Item)
Asm–Index numbers not used: 27 to 29, and 34 to 39
Chapter 8. Parts Catalog 574
Assembly 12: Electrical I
hc2m312F
43 42
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Chapter 8. Parts Catalog 575
Table 77. Assembly 12: Electrical I
Asm–Index Grid
PartNumber Units Description
12– Electrical I
–1 A3 90H3308 1 Interlock switch
–2 B1 90H3309 1 Fuser cover switch
–3 A2 90H3310 2 Fan
–4 C3 90H3311 1 Low voltage power supply (100/110V)
–4 C3 90H3312 1 Low voltage power supply (220V)
–5 C2 NP 1 Inlet holder
–6 A3 90H3313 1 Duplex interface PWB
–7 A2 NP 1 Fan duct
–8 C3 07L0039 1 MCU PWB (100V)
–8 C3 90H3314 1 MCU PWB (110V)
–8 C3 07L0040 1 MCU PWB (220V)
–9 B3 NP 1 MCU holder
–10 B3 NP 1 HVPS spacer
–11 A3 90H3315 1 High voltage power supply
–12 A4 NP 1 Knob volume
–13 B2 11L5355 1 Fuser cover harness
–14 C4 90H3316 1 LVPS harness
–15 A4 90H3317 1 HVPS harness
–16 B4 90H3318 1 ROS harness
Chapter 8. Parts Catalog 576
Table 77. Assembly 12: Electrical I (continued)
Asm–Index Grid
PartNumber Units Description
12– Electrical I
–17 C4 90H3319 1 Tray harness
–18 C4 11L5356 1 Toner relay harness
–19 C2 NP 1 Power cord
–20 C2 NP 1 Adapter
–21 B4 NP 1 Ferrite core1
–22 B1 NP 1 Clamp P
–23 C4 NP 2 Clamp F
–40 A1, A2 NP 2 Fan guard
–41 A1 NP 1 Bracket
–42 C4 11L6587 1 Fan, LVPS (7 Amp LVPS Only)
–43 C3 NP 1 Fan mounting bracket
Asm–Index numbers not used: 24 to 39
Chapter 8. Parts Catalog 577
Assembly 13: Electrical II
1 2 3 4
1 2 3 4
A
B
C
A
B
C
2
9
hc2m313F
3
5
5
7
8
6
Chapter 8. Parts Catalog 578
Table 78. Assembly 13: Electrical II
Asm–Index Grid
PartNumber Units Description
13– Electrical II
–2 A3 90H0703 1 Cage
–3 B2 90H0753 1 Bezel
–5 C1 NP 2 Panel cap
–6 B4 90H0705 1 Controller PWB
–7 C4 07L0041 1 Controller harness
–8 B4 90H3320 1 Console harness
–9 A4 NP 1 Panel
Asm–Index numbers not used: 1, 4
Chapter 8. Parts Catalog 579
Assembly 99: KitsTable 79. Assembly 99: Kits
Asm–Index Part Number Description
99– Kits
06L9997 Bearing kit
NP v Feed bearing (4-6)
NP v Turn bearing (4-13)
NP v Registration front bearing (7-15)
NP v Registration back bearing (7-16)
NP v Drive left bearing (10-8)
90H3380 Spring kit
NP v Turn chute spring (3-3)
NP v Feed spring (4-7)
NP v MSI normal force spring (5-6)
NP v Pick up spring (6-16)
NP v BTR left spring (7-4)
NP v BTR right spring (7-5)
NP v Full stack spring (8-9)
NP v Pop up spring, left (11-6)
NP v Pop up spring, right (11-7)
NP v Pop up latch (11-12)
Chapter 8. Parts Catalog 580
Table 79. Assembly 99: Kits (continued)
Asm–Index Part Number Description
99– Kits
NP v CRU latch spring (11-14)
NP v ROS push spring (11-17)
90H3384 Gear kit
NP v Turn gear (4-12)
NP v Turn idler gear (4-14)
NP v Feed idler gear (4-15)
NP v Out idler gear (4-16)
NP v Pick up gear (6-15)
NP v Registration in gear (7-12)
NP v Registration front gear (7-13)
NP v Registration back gear (7-14)
11L5322 Hardware kit
NP v Screw ’S’ (machine, collared, 6mm)
NP v Screw ’X’ (self-tapping, collared, 8mm)
NP v Screw ’X’ (machine, collared, 10mm)
v Thumbscrews
11L5321 Duplex bearing kit
NP v Duplex bearing (31-10)
NP v Duplex bearing (31-13)
Chapter 8. Parts Catalog 581
Table 79. Assembly 99: Kits (continued)
Asm–Index Part Number Description
99– Kits
NP v Pulley gear(31-14)
NP v Duplex collar (31-15)
07L0026 Repack/Relocation kit
NP v Box and packing materials
06L9998 Duplex gear kit
NP v One-way gear (31-17)
NP v Duplex gear D (31-18)
NP v Duplex gear C (31-19)
NP v Duplex gear B (31-20)
NP v Duplex gear A (31-21)
NP v Offset gear (31-22)
90H0781 Feed core kit
NP v Feed core (4-3)
NP v Feed core spring (4-4)
NP v Feed gear (4-5)
NP v Feed spring (4-7)
90H0800 Retard pad kit
NP v Retard pad (6-18)
NP v Retard pad spring (6-19)
Chapter 8. Parts Catalog 582
Table 79. Assembly 99: Kits (continued)
Asm–Index Part Number Description
99– Kits
90H3290 Registration actuator kit
NP v Registration sensor (7-6)
NP v Registration actuator (7-7)
NP v Registration spring (7-8)
NP v Registration sensor bracket (7-9)
90H3478 Rear cover kit
NP v Rear cover (42-2)
NP v Spring (42-4)
NP v Paper chute (42-5)
NP v Strap (42-33)
90H3479 Transport roll kit
NP v Transport roll (42-7)
NP v Right hand lock (42-8)
NP v Left hand lock (42-24)
NP v Spacer (42-35)
NP v E-ring
NP v KL-Clip
90H3480 Feed roller kit
NP v Feed roller (42-14)
Chapter 8. Parts Catalog 583
Table 79. Assembly 99: Kits (continued)
Asm–Index Part Number Description
99– Kits
NP v Feed roller bracket (42-15)
NP v Right hand feed roller bracket (42-16)
NP v Left hand feed roller bracket (42-17)
11L5352 Kit connector kit
NP v Connector harness (42-30)
NP v Screw (42-31)
Chapter 8. Parts Catalog 584
Assembly 100: FirmwareTable 80. Assembly 100: Firmware
Asm–Index Part Number Description
100– Firmware
–1 90H0705 Controller
–2 90H0703 Cage
–3 90H0753 Bezel
–4 11L5325 PCL/PS SIMM (8MB)
–5 11L5326 IPDS SIMM
–7 11L5327 Twinax card
–8 11L5328 Coax card
–9 63H2837 Ethernet card
–10 63H2834 T/R card
–11 90H0610 Hard drives
–12 63H2443 Macro flash (2MB)
–13 63H2444 Macro flash (4MB)
–14 63H2463 DRAM (4MB)
–15 63H2465 DRAM (8MB)
–16 63H2467 DRAM (16MB)
–17 63H2469 DRAM (32MB)
–18 07L0023 PCL SIMM – Simplified Chinese DBCS
Chapter 8. Parts Catalog 585
Table 80. Assembly 100: Firmware (continued)
Asm–Index Part Number Description
100– Firmware
–19 07L0022 PCL SIMM – Traditional Chinese DBCS
–20 07L0021 Japanese Heisei Fonts
–21 11L6581 PAGES/ESCP SIMM (8MB)
–22 11L6624 PCL/PS SIMM (8MB) for 4320-003
Chapter 8. Parts Catalog 586
Miscellaneous Items
Commonly Used PartsDescription Part Number Asm–Index / Page Units
Pick up roll kit 90H0798 6-8 1
MSI (auxiliary tray) retard (separation) pad 90H0800 6-18 1
MCU PWB 90H3314 12-8 1
Fan 90H3310 12-3 1
Fuser assembly, 100 VAC (supply item) 90H3465 8-1 1
Fuser assembly, 110 VAC (supply item) 90H0750 8-1 1
Fuser assembly, 220 VAC (supply item) 90H0751 8-1 1
High-voltage power supply assembly 90H3315 12-8 1
Low-voltage power supply, 100/110 VAC 90H3311 12-4 1
Low-voltage power supply, 220 VAC 90H3312 12-4 1
Controller 90H0705 13-6, 100-1 1
Chapter 8. Parts Catalog 587
Commonly Used FastenersWhere Used Description Part Number
Fan Screw, M3x30, no washer
Internal paper handling Screw, M4x10, black-L9, head
Laser/scanner Screw, M3x20, brass colored
Main motor (MT1) M4x8, formed washer
Metal parts M3x6, formed washer
Plastic parts M3x6, double washer
ToolsThere are no special tools required to service the IBM InfoPrint 20.
Cleaners and LubricantsThe following cleaners and lubricants are approved for use with this printer:
Item Use Part Number Remarks
Cleaner Cleaning metal parts 2286522 Solvent based cleaner
Cover cleaner Cleaning plastic, rubber, and externalparts
6933028 Water based, mild detergent
Grease Lubricating gear teeth 1280441 General purpose grease, mediumweight
Oil Lubricating gear shafts and bearings 1280443 General purpose oil, medium viscosity
Chapter 8. Parts Catalog 588
Appendix A. FeaturesStandard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
Standard Featuresv Printing speed of up to 20 pages per minutev Resolution of 600 dots per inch (dpi), switchable to 1200 dpi emulationv PCL5e supportv Adobe PostScript 3v 4MB of memoryv Parallel interface (IEEE Std 1284-1994)v 500-sheet paper trayv 150-sheet auxiliary trayv 500-sheet paper output binv Printer drivers
Optional FeaturesFeature Feature Number Part Number
Duplex Unit 4402 90H0716
Paper Drawer/500-Sheet A4/Letter 4501 90H0717
Paper Drawer/500-Sheet A3/Ledger 4502 90H3341
500-Sheet Tray - A4/Letter 4503 90H0718
© Copyright IBM Corp. 1998 589
Feature Feature Number Part Number
500-Sheet Tray - A3/Ledger 4504 90H0719
2,000 Sheet Input Drawer 4620 90H0720
Envelope Tray 4511 90H0721
Network Card for Token-Ring 4120 06L9835
Network Card for Ethernet 4161 06L9838
IBM IPDS SIMM 4820 90H0746
IBM Coax SCS Interface 4171 06L9846
IBM Twinax SCS Interface 4141 06L9849
4MB Memory SIMM 4304 63H2463
8MB Memory SIMM 4308 63H2465
16MB Memory SIMM 4316 63H2467
32MB Memory SIMM 4332 63H2469
2MB Flash Memory 4030 63H2443
4MB Flash Memory 4032 63H2444
Hard Drive 4320 90H0610
PC Parallel Cable 63H1956
Software CD Kit 90H0749
Operator Panel Overlays 90H3335
6 ft US (Chicago) Line Cord 6952301
Japanese Heisei Font 4810 07L0012
PAGES & ESC/P SIMM 4840 11L6578
Appendix A. Features 590
Appendix B. SuppliesOrdering Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592
Ordering SuppliesIn the U.S.A. or Canada, order printing supplies from IBM Printer Supplies, 1-888-IBM PRINT(1-888-426-7746).
In Europe, call IBM Supplies Fulfillment Operations at 31-43-3502756, or at one of the following numbers:v Denmark: 80015534v Finland: 08001-13110v France: 05-905871v Germany: 0130 818005v Italy: 1-678 78349v Norway: 800-11389v Sweden: 020-794270v United Kingdom: 0800-968679
© Copyright IBM Corp. 1998 591
Part NumbersThe customer is responsible for buying and replacing the following supplies.
Supply Average Yield Part Number
EP (Toner) Cartridge 14,000 impressions 90H0748
Usage Kit (100 Volt) 200,000 impressions 90H3465
Usage Kit (110 Volt) 200,000 impressions 90H0750
Usage Kit (230 Volt) 200,000 impressions 90H0751
Notes:1. For the EP (Toner) cartridge and usage kits, the approximate average yield has been established with a coverage of 5
percent. An impression is defined as one side of a printed letter-size page with a 1/2″ border around the page. A duplexpage is defined as two impressions.A toner cartridge can print approximately 14,000 pages of Letter-size paper, containing text or graphics that cover 5% of thepage. Depending on the type of printing you do, you can obtain up to double the page yield if you use the ECONO settingfor the QUALITY item on the Config Menu or if you select toner saver print quality mode from your printer driver. (Note thatthe driver setting will override the menu setting.) For example, using ECONO and a density setting of 1, you may be able toprint up to 28,000 images at 5% coverage.Note: The actual page yield is affected by the environment, the type of print media, the percentage of text and graphics,the complexity of the graphics, and other factors.
2. The usage kit includes a fuser assembly and transfer charging (BTR) roller assembly.
Appendix B. Supplies 592
Appendix C. Media SpecificationsAttention:
Please use print materials that conform to the specifications listed in the following sections. Usingnon-conforming print materials can decrease page yield, cause jams, and damage your printer.
The following sections contain information about selecting print materials, including:v “Auxiliary Tray Paper Specifications” on page 595
v “A4/Letter Tray Paper Specifications” on page 598
v “A3/Ledger (11 inches x 17 inches) Tray Paper Specifications” on page 599
v “Envelope Tray Paper Specifications” on page 601
v “2000-Sheet Input Drawer Paper Specifications” on page 601
Notes:
1. The following media weights are supported:v Paper trays: 16-28 pound (60-105 grams/meter²)v Envelope tray: 16-28 pound (60-105 grams/meter²)v Auxiliary tray:
– Paper, labels, transparencies, envelopes: 60-135 grams/meter²– Japanese Official Postcard: 190 grams/meter²
v 2000-Sheet Input Drawer: 16-28 pound paper (60-105 grams/meter²)2. Do not use the following types of paper and printable material in your printer:v Multipart formsv Stapled, folded, or wrinkled paperv Smooth or coated paper
© Copyright IBM Corp. 1998 593
3. Use the auxiliary tray to print transparencies or labels. Do not feed these types of print media from thepaper trays.
4. Some recycled papers release paper dust that can accumulate and cause frequent paper jams andreduced supplies life.
5. High humidity can damage paper. Try to store paper where it is cool and dry.
Appendix C. Media Specifications 594
Auxiliary Tray Paper Specifications
Style Size DuplexShort-edge feed
(SEF)Long-edge feed
(LEF)
Paper
Letter8.5 x 11 in215.9 x 279.4 mm
Yes Yes Yes
Legal8.5 x 14 in215.9 x 355.6 mm
Yes Yes No
Folio8.5 x 13 in215.9 x 330.2 mm
Yes Yes No
11 x 1711 x 17 in279.4 x 431.8 mm
Yes Yes No
A48.27 x 11.69 in210 x 297 mm
Yes Yes Yes
B5-JIS7.16 x 10.12 in182 x 257 mm
No Yes Yes
B410.12 x 14.33 in257 x 364 mm
Yes Yes No
A55.85 x 8.27 in148.5 x 210 mm
No No Yes
Appendix C. Media Specifications 595
Style Size DuplexShort-edge feed
(SEF)Long-edge feed
(LEF)
A311.69 x 16.54 in297 x 420 mm
Yes Yes No
Executive7.25 x 10.25 in184.2 x 266.7 mm
No No Yes
Statement5.5 x 8.5 in139.7 x 215.9 mm
No No Yes
Custom formsMinimum:
3.5 x 5.8 in88 x 148 mm
Maximum:13 x 20 in330 x 508 mm
No Yes No
Envelopes and Postcards
Japanese Official Postcard (Hagaki)3.94 x 5.83 in100 x 148 mm
No Yes No
Monarch3.875 x 7.5 in98.4 x 190.5 mm
No Yes No
COM104.125 x 9.5 in104.8 x 241.3 mm
No Yes No
Appendix C. Media Specifications 596
Style Size DuplexShort-edge feed
(SEF)Long-edge feed
(LEF)
C56.38 x 11.77 in162 x 229 mm
No Yes No
DL4.33 x 8.66 in110 x 220 mm
No Yes No
Custom envelopesMinimum:
3.5 x 5.8 in88 x 148 mm
Maximum:13 x 20 in330 x 508 mm
No Yes No
Appendix C. Media Specifications 597
A4/Letter Tray Paper Specifications
Style Size
LTR Paper Group A4 Paper Group
Duplex SEF LEF Duplex SEF LEF
Letter8.5 x 11 in215.9 x 279.4 mm
Yes Yes Yes Yes No Yes
A48.27 x 11.69 in210 x 297 mm
Yes No Yes Yes Yes Yes
B5-JIS7.16 x 10.12 in182 x 257 mm
Not supported No No Yes
A55.85 x 8.27 in148.5 x 210 mm
Not supported No No Yes
Executive7.25 x 10.25 in184.2 x 266.7 mm
No No Yes Not supported
Statement5.5 x 8.5 in139.7 x 215.9 mm
No No Yes Not supported
Appendix C. Media Specifications 598
A3/Ledger (11 inches x 17 inches) Tray PaperSpecifications
Style Size
LTR Paper Group A4 Paper Group
Duplex SEF LEF Duplex SEF LEF
Letter8.5 x 11 in215.9 x 279.4 mm
Yes Yes Yes Yes No Yes
Legal8.5 x 14 in215.9 x 355.6 mm
Yes Yes No Yes Yes No
Folio8.5 x 13 in215.9 x 330.2 mm
Yes Yes No Yes Yes No
11 x 1711 x 17 in279.4 x 431.8 mm
Yes Yes No Yes Yes No
A48.27 x 11.69 in210 x 297 mm
Yes No Yes Yes Yes Yes
B5-JIS7.16 x 10.12 in182 x 257 mm
Not supported No No Yes
B410.12 x 14.33 in257 x 364 mm
Yes Yes No Yes Yes No
Appendix C. Media Specifications 599
Style Size
LTR Paper Group A4 Paper Group
Duplex SEF LEF Duplex SEF LEF
A55.85 x 8.27 in148.5 x 210 mm
Not supported No No Yes
A311.69 x 16.54 in297 x 420 mm
Yes Yes No Yes Yes No
Executive7.25 x 10.25 in184.2 x 266.7 mm
No No Yes Not supported
Statement5.5 x 8.5 in139.7 x 215.9 mm
No No Yes Not supported
Appendix C. Media Specifications 600
Envelope Tray Paper Specifications
Style Size DuplexShort-edge feed
(SEF)Long-edge feed
(LEF)
Monarch3.875 x 7.5 in98.4 x 190.5 mm
No Yes No
COM104.125 x 9.5 in104.8 x 241.3 mm
No Yes No
C56.38 x 11.77 in162 x 229 mm
No Yes No
DL4.33 x 8.66 in110 x 220 mm
No Yes No
2000-Sheet Input Drawer Paper Specifications
Style Size DuplexShort-edge feed
(SEF)Long-edge feed
(LEF)
Letter8.5 x 11 in215.9 x 279.4 mm
Yes No Yes
A48.27 x 11.69 in210 x 297 mm
Yes No Yes
Appendix C. Media Specifications 601
Appendix D. Technical SupportIBM Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602Technical Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602Obtaining Documents, Drivers, and Utilities from the World Wide Web . . . . . . . . . . . . . . . . . . . .603Obtaining Code Updates from the World Wide Web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603Dealer Warranty Claim Center (DWCC)—U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603Printer Sales Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603
IBM Warranty InformationWarranty period: 12 months
Warranty offerings: On-site:v Dealerv IBM service
Technical Support NumbersIBM customer support for this printer is available at no charge when covered by an IBM maintenanceagreement or the IBM one-year warranty period. If the printer requires repair, the support representative willexplain the customer’s options.v U.S.A. and Canada: 1-800-358-6661.v Outside the U.S.A. and Canada, customers should call their country customer service center numbers.
© Copyright IBM Corp. 1998 602
Obtaining Documents, Drivers, and Utilities from theWorld Wide WebTo obtain current versions of the InfoPrint 20 documentation, printer drivers, utilities, and programs, thecustomer can do the following:1. Access the IBM Printing Systems Company home page:
http://www.printers.ibm.com
2. Navigate to the document, printer driver, utility, or program needed and follow the instructions to downloadit.
Obtaining Code Updates from the World Wide WebTo obtain code updates for the InfoPrint 20, if required, the customer can do the following:1. Access the IBM Printing Systems Company home page:
http://www.printers.ibm.com
2. Navigate to the code update needed and follow the instructions to download it.
Dealer Warranty Claim Center (DWCC)—U.S.A. onlyTo order warranty parts and request warranty claim reimbursements through the Dealer Warranty ClaimsCenter, call: 1-800-388-7080
Printer Sales InformationIBM Printer Remarketer: 1-800-793-5888 (U.S.A.) or IBM country remarketer.
Appendix D. Technical Support 603
Appendix E. Duplex Unit OptionDiagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
09 DUPLEX COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60722 PAPER JAM (or 21 PAPER JAM from Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60829 OUTPUT FULL, with Duplex Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .610
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614Removal Procedures, Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615
Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616
Duplex Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
Duplex Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
Duplex Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .621Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622
Duplex Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .623Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .623Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626
Duplex PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .628
© Copyright IBM Corp. 1998 604
Duplex Cover Switch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .630
Duplex Cover Switch2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .632
Duplex Pass Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .633Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .633Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .634
Duplex Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636
Duplex Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638
Offset Guide Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640
Offset Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643
Duplex Upper Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .646
Duplex Lower Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649
Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651
Appendix E. Duplex Unit Option 605
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652Assembly 30: Duplex Unit and Offset Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652Assembly 31: Duplex Unit and Offset Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655
Appendix E. Duplex Unit Option 606
DiagnosticsIf the problem involves only duplex printing, install a new duplex unit.
09 DUPLEX COVER OPENOne of the duplex covers is open. Ensure that both covers are closed correctly. Also ensure that the option isinstalled correctly and plugged tightly to the connector on the Duplex Interface PWB.Table 81. 09 DUPLEX COVER OPEN
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Duplex Option (Asm-Index: 30-1, page 652)
v Duplex Interface PWB (Asm-Index: 12-6, page 575)
v MCU
Appendix E. Duplex Unit Option 607
22 PAPER JAM (or 21 PAPER JAM from Duplex)There was a paper jam at the duplex option.Table 82. 22 PAPER JAM
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Duplex Option (Asm-Index: 30-1, page 652)
1.
DUPLEX OPTION
Check for dirty rolls, obstructions, broken actuators, etc.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem job prints.
Go to step 2
2.
DUPLEX OPTION
Install a new Duplex Option (see page “Duplex Unit” on page 615).Note: The following diagnostics are available:
v Sensors – “D21 SENSOR TEST” on page 261
v Duplex Motor – “D63 MOTOR D CW (Duplex Motor Runs CW)” onpage 287 and “D64 MOTOR D CCW (Duplex Motor Runs CCW)” onpage 289
Is the problem fixed?
Verify the fix. Alsoverify that theproblem job prints.
Go to “SkewedImage” onpage 212
Appendix E. Duplex Unit Option 608
Table 82. 22 PAPER JAM (continued)
Step Actions and Questions Yes No
3.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do notfind a solution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Appendix E. Duplex Unit Option 609
29 OUTPUT FULL, with Duplex InstalledWithout a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index:8-8, page 564) within the Fuser Assembly. When a duplex option is installed, the printer monitors the DuplexStack Actuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator.
When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed onthe operator panel. The printer will continue to print a few more pages to clear the paper path before it stops.The 29 OUTPUT FULL message remains until the signals indicate that the the paper stack has beenremoved.
Notes:
1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printer willstop after the paper path clears.
2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the customer can probably removethe duplex unit and continue to print simplex jobs.
Table 83. 29 OUTPUT FULL, with Duplex Installed
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Duplex Full Stack Actuator (Asm-Index: 30-18, page 652)
v Duplex Unit (Asm-Index: 30-1, page 652)
v Duplex Interface PWB (Asm-Index: 12-6, page 575)
v MCU PWB (Asm-Index: 12-8, page 575)
Appendix E. Duplex Unit Option 610
Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)
Step Actions and Questions Yes No
1.
SENSOR TESTa. Use “D21 SENSOR TEST” on page 261 to check the Duplex Full
Stack Actuator and Sensor.
b. Press and release the actuator.
Is the sensor OK?
Possibleintermittent orMCU problem
Go to step 2
2.
DUPLEX STACK ACTUATORa. Unplug the duplex option from the back of the printer.b. Carefully remove the option from the printer.c. Place the option on a table.d. Manually actuate the Duplex Stack Acutator and observe the Duplex
Stack Sensor at the other end of the actuator. Look for debris thatcould obstruct the actuator or sensor.
Are the actuator and sensor OK?
Go to step 3 Repair as neededor install a newDuplex Unit.
3.
DUPLEX UNIT INSTALLATIONa. Carefully install the duplex option on the printer. Tighten the
thumbscrews.b. Plug the duplex option into the printer connection and tighten the
thumbscrews.c. Run TEST MENU/CONTINUOUS TEST for about 10 pages. Then
press the CANCEL key (the printer will print many more pages beforestopping).
Does the 29 OUTPUT FULL message display?
Go to Step 4Problem appearsfixed. Verify thefix. Also verify thatthe problem jobprints.
Appendix E. Duplex Unit Option 611
Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)
Step Actions and Questions Yes No
4.
DUPLEX UNITa. Install a new (or borrowed) duplex unit.
Note: The printer can probably continue to be used without the duplexunit if a new duplex unit is needed but not immediately available.
b. Repeat the D21 test
Is the sensor OK?
The originalduplex unit wasbad.
Go to Step 5
5.
FULL STACK SENSING WITHOUT THE DUPLEX UNITa. Remove the duplex unit.b. Repeat D21, activating the base Full Stack Actuator (at the fuser asm).
Is the sensor OK?
Go to Step 6 The onlycomponent sharedby the Full Stacksensor and theDuplex Full StackSensor circuits isthe MCU. Install anew MCU.
6.
Install a new Duplex Interface PWB (See page 615).
Ensure that the connection at the MCU is completely seated- it can lookconnected when it is not.
Is the problem fixed?
Verify the fix. Alsoverify that theproblem job prints.
Install a new MCU
Appendix E. Duplex Unit Option 612
Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)
Step Actions and Questions Yes No
7.
End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:
– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)
– Environmental conditions (temperature, humidity, ventilation)
If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do notfind a solution, call your next level of support (see “Appendix D. Technical Support” on page 602).
Appendix E. Duplex Unit Option 613
Wiring Diagram
HC2M815F
DUPLEX INTERFACE PWB
DUPLEX PWB
MCU
P/J192
P/J193
P/J198
P/J184
P/J186 P/J187
P/J18
P/J20
P182
P183
DUP STACKSENSOR
OFFSETMOTOR
DUPLEX PASSSENSOR
DUPLEXMOTOR
DUP COVERSWITCH 1
DUP COVERSWITCH 2
P/J196 P/J197 P/J195
MM
Appendix E. Duplex Unit Option 614
Removal Procedures, Adjustments
Duplex UnitAsm-Index: 30-1, page 652.
J182 hc2m758F
21
3
3
Figure 82. Duplex Unit Removal
Appendix E. Duplex Unit Option 615
Removal1. Switch off printer power and unplug the power cord from the wall.2. Disconnect J182 of the duplex cable (Asm-Index: 30-23, page 652) from the rear of the base engine.
3. Remove the paper weight (1) (Asm-Index: 30-30, page 652) from the duplex front cover (2) (Asm-Index:30-7, page 652).
4. Loosen the two knurled screws (3) on the back side of the duplex unit.5. Lift the duplex unit up back and remove it from the base engine.6. Lay the duplex unit on a flat surface holding inside up.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 616
Duplex Left CoverAsm-Index: 30-3, page 652.
J182hc2m759F
3
3
2 1
5
4
Figure 83. Duplex Left Cover Removal
Appendix E. Duplex Unit Option 617
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the E-ring (1) holding the left side knurled screw (2).4. Loosen (do not remove) the two screws (3) securing the duplex left cover (4).5. Place the duplex unit on a flat surface left side up.6. Tilt the duplex left cover backward and loosen the hook (5) of the left cover from the frame of the duplex
unit.7. Remove the cable from the slot in the left end cover.8. Lift the left cover and remove it from the duplex unit.9. Lay the duplex unit on a flat surface inner side up.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 618
Duplex Right CoverAsm-Index: 30-4, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
hc2m760F
1
3
24
5
3
Figure 84. Duplex Right Cover Removal
Appendix E. Duplex Unit Option 619
3. Remove the E-ring (1) holding the right side knurled screw (2).4. Loosen (do not remove) the two screws (3) securing the duplex right cover (4).5. Place the duplex unit right side up.6. Open the duplex lower cover (Asm-Index: 30-6, page 652).
7. Tilt the duplex right cover backward and loosen the hook (5) of the right cover from the frame of theduplex unit.
8. Lift the right cover and remove it from the duplex unit.9. Close the lower cover.
10. Lay the duplex unit on a flat surface inside up.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 620
Duplex Upper CoverAsm-Index: 30-5, page 652.
hc2m761
1
2
Figure 85. Duplex Upper Cover Removal
Appendix E. Duplex Unit Option 621
Removal1. Switch off printer power and unplug the power cord from the wall.2. Hold the duplex upper cover (1) half open.3. Remove the duplex straps (2) (Asm-Index: 30-22, page 652) from the duplex unit (Asm-Index: 30-1, page
652).
4. Slide the upper cover to the left up, and release the right side hinge boss from the frame of the duplex unitpressing the arm inside using a flat blade screwdriver, if necessary.
5. Remove the left side hinge boss from the frame.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 622
Duplex Lower CoverAsm-Index: 30-6, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Hold the duplex lower cover (1) half open.3. Slide the lower cover to the left up, then remove the right side hinge boss from the frame of the duplex
unit (Asm-Index: 30-1, page 652) pressing the arm inside using a flat blade screwdriver, if necessary.
hc2m762F
1
Figure 86. Duplex Lower Cover Removal
Appendix E. Duplex Unit Option 623
4. Remove the left side hinge boss from the frame.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 624
Offset MotorAsm-Index: 30-21, page 652.
J186
hc2m764F
1
2
Figure 87. Offset Motor Removal
Appendix E. Duplex Unit Option 625
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the duplex left cover (See page 617).
4. Disconnect the J186 of the offset motor (1) (Asm-Index: 30-21, page 652) from the duplex PWB(Asm-Index: 30-10, page 652).
5. Place the duplex unit left side up.6. Remove the two screws (2) securing the offset motor.7. Remove the motor from the frame of the duplex unit tilting the motor slightly to the right so that the lever
leaves the offset guide arm (Asm-Index: 30-20, page 652).
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 626
Duplex PWBAsm-Index: 30-10, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the duplex left cover (See page 617).
J182
J183
J187J184
hc2m765F
1
2
2
2
Figure 88. Duplex PWB Removal
Appendix E. Duplex Unit Option 627
4. Remove the offset motor (See page 625).
5. Disconnect P/Js below from the duplex PWB (1).v J183 of the duplex sensor harness (Asm-Index: 30-15, page 652)
v J184 of the duplex sensor harness (Asm-Index: 30-15, page 652)
v J187 of the duplex motor harness (Asm-Index: 30-14, page 652)
6. Remove the four screws (2) securing the duplex PWB and remove it from the frame of the duplex unit.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 628
Duplex Cover Switch1Asm-Index: 30-11, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the duplex upper cover (Asm-Index: 30-5, page 652).
J193
hc2m766F
1
Figure 89. Duplex Cover Switch1 Removal
Appendix E. Duplex Unit Option 629
3. Nip the duplex cover switch 1 (1) in a vertical direction and remove it from the frame of the duplex unit(Asm-Index: 30-1, page 652).
Attention: Be careful not to damage the duplex sensor harness (Asm-Index: 30-15, page 652).
4. Disconnect J193 of the duplex sensor harness from the switch.
Replacement1. Open the duplex upper cover.2. Reconnect J193 of the duplex sensor harness to the duplex cover switch1.3. Push the switch into the opening in the frame until the switch snaps in place.4. Route the wires of the harness inside the frame of the duplex unit.5. Close the duplex upper cover.
Note: Ensure that the tab on the duplex upper cover presses the switch.
Appendix E. Duplex Unit Option 630
Duplex Cover Switch2Asm-Index: 30-12, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Disconnect J198 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex cover switch2 (1).
4. Remove the duplex lower cover (See page 623).
J198
hc2m767F
1
Figure 90. Duplex Cover Switch2 Removal
Appendix E. Duplex Unit Option 631
5. Nip the duplex cover switch2 in a vertical direction from the back side of the duplex unit (Asm-Index: 30-1,page 652), using a needle nosed pliers if necessary, and pull the switch out from the frame of the duplexunit.
Replacement1. Lay the duplex unit back side up.2. Push the duplex switch2 into the opening in the frame of the duplex unit until the switch snaps in place.3. Reconnect J198 of the duplex sensor harness to the switch.4. Route the wires of the harness inside of the frame of the duplex unit.5. Reinstall the duplex lower cover (See page 623).
6. Close the duplex lower cover (Asm-Index: 30-6, page 652).
Note: Ensure that the tab of the duplex lower cover presses the duplex cover switch2.
7. Reinstall the duplex unit (See page 615).
Appendix E. Duplex Unit Option 632
Duplex Pass SensorAsm-Index: 30-13, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Disconnect J195 from the duplex pass sensor (1).4. Nip the hooks of the sensor and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652).
J195
hc2m768F
1
Figure 91. Duplex Pass Sensor Removal
Appendix E. Duplex Unit Option 633
Replacement1. Lay the duplex unit inside up.2. Push the duplex pass sensor into the hole in the frame until the sensor snaps in place.3. Reconnect J195 to the sensor.
Note: Ensure that the harness wires are in the hanger.4. Reinstall the duplex unit (See page 615).
Appendix E. Duplex Unit Option 634
Duplex Stack SensorAsm-Index: 30-17, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex upper cover (See page 621).
3. Remove the duplex unit (See page 615).
4. Remove the duplex left cover (See page 617).
5. Remove the duplex right cover (See page 619).
6. Remove the duplex front cover.7. Lay the duplex unit (Asm-Index: 30-1, page 652) inside up on a pillow so that the actuator of the duplex
pass sensor (Asm-Index: 30-13, page 652) does not touch the floor.
J192
hc2m769F
1
Figure 92. Duplex Stack Sensor Removal
Appendix E. Duplex Unit Option 635
8. Disconnect J192 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex stack sensor(1).
9. Nip the hooks of the stack sensor and remove it from the duplex eliminator assembly (Asm-Index: 30-16,page 652).
Replacement1. Lay the duplex unit inside up on a pillow so that the actuator of the duplex pass sensor does not touch the
floor.2. Push the duplex stack sensor into the opening until the sensor snaps in place.3. Reconnect J192 of the duplex sensor harness to the sensor.4. Route the wires of harness into the frame of the duplex unit.5. Reinstall the duplex front cover.6. Reinstall the duplex right cover (See page 619).
7. Reinstall the duplex left cover (See page 617).
8. Reinstall the duplex unit (See page 615).
9. Reinstall the duplex upper cover (See page 621).
Appendix E. Duplex Unit Option 636
Duplex Stack ActuatorAsm-Index: 30-18, page 652.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove duplex unit (See page 615).
3. Lay the duplex unit inside up.4. Nip the center of the bar of the duplex stack actuator (1) using a needle nosed pliers and pull the bar to
flex it.5. Remove the right end of the bar (opposite side of the duplex stack sensor) (Asm-Index: 30-17, page 652)
from the hole on the frame of the duplex eliminator assembly (Asm-Index: 30-16, page 652).
hc2m770F
1
Figure 93. Duplex Stack Actuator Removal
Appendix E. Duplex Unit Option 637
6. Turn the lever of the actuator up so that the shielding flag of the actuator leaves from the stack sensor.7. Slide the actuator to the right and remove the bar from the hole of the duplex eliminator.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 638
Offset Guide ArmAsm-Index: 30-20, page 652.
Note: This procedure is applicable only to the models with the offset Function.
hc2m772F
1 2
Figure 94. Offset Guide Arm Removal
Appendix E. Duplex Unit Option 639
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex upper cover (See page 621).
3. Remove duplex unit (See page 615).
4. Remove duplex left cover (See page 617).
5. Lay the duplex unit inside up on a pillow so that the duplex pass sensor (Asm-Index: 30-13, page 652)does not touch the floor.
6. Tilt the lever of the offset motor (Asm-Index: 30-21, page 652) toward the outside of the duplex unit.
7. Remove the screw (1) securing the offset guide arm (2).8. Slide the offset guide arm slightly toward the front so that it leaves the lever of the offset motor and
remove the arm from the frame.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 640
Offset AssemblyAsm-Index: 31-6, page 655.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex upper cover (See page 621).
hc2m773F
1
12
Figure 95. Offset Assembly Removal (1)
Appendix E. Duplex Unit Option 641
3. Remove the duplex unit (See page 615).
4. Remove the duplex left cover (See page 617).
5. Remove the duplex right cover (See page 619).
Note: Step 6 is applicable only to the models without the offset function.
6. Remove the offset hold arm.
Note: Step 7 is applicable only to the models with the offset function.7. Remove the offset guide arm (See page 639).
8. Lay the duplex unit top side down.9. Remove the two screws (1) securing the duplex support assembly (2) (Asm-Index: 31-4, page 655).
10. Remove the duplex support assembly together with the duplex guide (Asm-Index: 30-8, page 652).
11. Slide the offset assembly (3) right and left and remove the four bearings (4) from the frame of the duplexunit.
12. Lift the right end of the offset assembly in the direction of the cutout in the frame and release the twoshafts from the frame of the duplex unit.
13. Slide the offset assembly to the right and remove it with the four duplex bearings (Asm-Index: 31-10,page 655) and two offset gears (5) (Asm-Index: 31-22, page 655) from the frame.
Appendix E. Duplex Unit Option 642
Replacement1. Lay the duplex unit top side down.2. Turn the duplex stack actuator so that the tip of the lever directs to the top of the duplex unit.3. Hold the shafts of the offset assembly with the gear side to the right.4. Set two duplex bearings and the offset gear to each shaft in the order below from left side of the shaft.v duplex bearing - (collar right)v duplex bearing - (collar left)v offset gear - (collar left)
5. Insert the left ends of the shafts of the offset assembly into the openings in the frame of the duplex unit.6. Insert the right side of the shafts of the offset assembly placing the four bearings inside and two gears
outside of the frame making sure that the gear collars are on the inside of the large gear (See Figure 99on page 650).
hc2m774F
4
4
3
5
4
Figure 96. Offset Assembly Removal (2)
Appendix E. Duplex Unit Option 643
7. Slide the body of the left side bearings and insert them into the openings in the frame until the collarstouch the frame.
8. Place the left side of the duplex support assembly so that its left end fixes the left side bearings.9. Slide the body of the right side bearings and insert them into the openings in the frame until the collars
touch the frame.10. Place the right side of the duplex support assembly.11. Secure the duplex support assembly using two screws (silver, 6mm).
Note: Step 12 is applicable only to the models without the offset function.12. Reinstall the offset hold arm.
Note: Step 13 is applicable only to the models with the offset function.13. Reinstall the offset guide arm (See page 639).
14. Reinstall the duplex right cover (See page 619).
15. Reinstall the duplex left cover (See page 617).
16. Reinstall the duplex chute (See page 615).
17. Reinstall the duplex upper cover (See page 621).
Appendix E. Duplex Unit Option 644
Duplex Upper RollAsm-Index: 31-11, page 655.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the duplex left cover (See page 617).
4. Remove the duplex right cover (See page 619).
5. Lay the duplex unit inside up.6. Disconnect P/J195 from the duplex pass sensor (Asm-Index: 30-13, page 652).
7. Release the harness from the harness collar (Asm-Index: 31-24, page 655).
hc2m775F
J195
Figure 97. Duplex Upper Roll Removal
Appendix E. Duplex Unit Option 645
8. Remove the harness collar from the duplex upper roll.9. Remove the left side clamp securing the duplex upper roll.
10. Remove the synchronize belt (Asm-Index: 31-16, page 655).
11. Remove the left side duplex collar (Asm-Index: 31-15, page 655).
12. Remove the pulley gear (Asm-Index: 31-14, page 655).
13. Remove the duplex gear ’D’ (Asm-Index: 31-18, page 655).
14. Remove the right side duplex collar and the duplex bearing (Asm-Index: 31-13, page 655).
15. Slide the duplex upper roll to the right and release the right side duplex bearing from the frame of theduplex unit.
16. Lift the right end of the duplex upper roll and remove its right end from the frame.17. Slide the upper roll to the right and pull out its left end from the frame.18. Release the hooks and the E-clip of the one way gear (Asm-Index: 31-17, page 655) using a small flat
blade screwdriver and remove the gear and the bearing from the shaft.
Replacement1. Lay the duplex unit inside up.2. Hold the shaft of the duplex upper roll with the gear side left.3. Insert the left end of the shaft of the upper roll into the opening in the frame of the duplex unit.4. Place right end of the shaft of the upper roll into the cutout in the frame.5. Place the duplex bearing (collar right) to the shaft from the outside of the frame.6. Insert the body of the right side duplex bearing into the opening of the frame.7. Place the one way gear from the right side end of the duplex upper roll until the gear snaps into place.8. Slide the upper roll to the left.9. Place the duplex bearing, the duplex collars and the pulley gear on the shaft of the upper roll from the
left side of the frame, in the order below.
Appendix E. Duplex Unit Option 646
v duplex bearing (collar left)v duplex collarv pulley gearv duplex collar
10. Secure the collars, etc. to the upper roll using a clamp.11. Reinstall the synchronize belt.12. Reinstall the harness collar to the duplex upper roll.13. Hook the harness of the duplex pass sensor to the harness collar.14. Reconnect P/J195 to the duplex pass sensor.15. Reinstall the duplex right cover (See page 619).
16. Reinstall the duplex left cover (See page 617).
Appendix E. Duplex Unit Option 647
Duplex Lower RollAsm-Index: 31-12, page 655.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the duplex left cover (See page 617).
4. Remove the duplex right cover (See page 619).
5. Lay the duplex unit inside up.6. Remove the left side clamp securing the duplex lower roll.
hc2m776F
Figure 98. Duplex Lower Roll Removal
Appendix E. Duplex Unit Option 648
7. Remove the synchronize belt (Asm-Index: 31-16, page 655).
8. Remove the left side duplex collar (Asm-Index: 31-15, page 655), the pulley gear (Asm-Index: 31-14,page 655), and the right side duplex bearing (Asm-Index: 31-13, page 655).
9. Slide the duplex lower roll to the right and release the right side duplex bearing from the frame.10. Lift the right end of the lower roll and remove its right end from the frame.11. Slide the lower roll to the right and pull out its left end from the frame.12. Release the E-ring and remove the duplex bearing from the right end of the shaft.
Replacement1. Lay the duplex unit inside up.2. Hold the shaft of the duplex lower roll with the pulley gear side left.3. Insert the left end of the shaft of the lower roll into the opening in the frame of the duplex unit.4. Insert the duplex bearing (collar right) to the shaft of the lower roll from the right end.5. Secure the bearing using an E-ring.6. Place the right end of the shaft of the lower roll placing the duplex bearing outside of the frame.7. Place the left side duplex bearing, the duplex collars and the pulley gear on the lower roll from the
outside of the frame, in the order below.v duplex bearing (collar left)v duplex collarv pulley gearv duplex collar
8. Secure the duplex collar, etc. to the lower roll using a clamp.9. Reinstall the synchronize belt.
10. Reinstall the duplex right cover (See page 619).
11. Reinstall the duplex left cover (See page 617).
Appendix E. Duplex Unit Option 649
Duplex MotorAsm-Index: 31-23, page 655.
J197 hc2m777F
1
2
2
Figure 99. Duplex Motor Removal
Appendix E. Duplex Unit Option 650
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).
3. Remove the duplex right cover (See page 619).
4. Lay the duplex unit inner side up.5. Disconnect J197 of the duplex motor harness (Asm-Index: 30-14, page 652) from the duplex motor (1).
6. Remove the two screws (2) securing the motor.7. Remove the duplex motor.
Replacement
Reverse the Removal procedure.
Appendix E. Duplex Unit Option 651
Parts Catalog
Assembly 30: Duplex Unit and Offset Feeder I
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m755F
Appendix E. Duplex Unit Option 652
Table 84. Assembly 30: Duplex Unit and Offset Feeder I
Asm–Index Grid
PartNumber Units Description
30– Duplex unit and offset feeder I
–1 A4 90H0716 1 Duplex unit (with 30-2∼30-30)
–2 B3 90H0716 1 v Duplex paper handling assembly (same as 31-1)
–3 A1 90H3359 1 v Duplex left cover
–4 B4 90H3360 1 v Duplex right cover
–5 A4 90H3361 1 v Duplex upper cover
–6 C3 90H3362 1 v Duplex lower cover
–7 A2 NP 1 v Duplex front cover
–8 C2, C3 NP 2 v Duplex guide
–9 C3 NP 1 v Duplex gate spring
–10 B1 90H3363 1 v Duplex PWB
–11 B2 90H3364 1 v Duplex cover switch 1
–12 C2 90H3365 1 v Duplex cover switch 2
–13 C2 90H3366 1 v Duplex pass sensor
–14 C1 90H3367 1 v Duplex motor harness
–15 B1 90H3368 1 v Duplex sensor harness
–16 B2 NP 1 v Duplex eliminator assembly
–17 B2 63H3079 1 v Duplex stack sensor
–18 B2 90H3370 1 v Duplex stack actuator
–19 B1 NP 1 v Offset hold arm
Appendix E. Duplex Unit Option 653
Table 84. Assembly 30: Duplex Unit and Offset Feeder I (continued)
Asm–Index Grid
PartNumber Units Description
30– Duplex unit and offset feeder I
–20 B1 90H3371 1 v Offset guide arm
–21 B1 90H3372 1 v Offset motor
–22 A3 90H3373 1 v Duplex strap
–23 C1 90H3374 1 v Duplex cable
–30 A2 90H3375 1 v Paper weight
Asm–Index numbers not used: 24 to 29
Appendix E. Duplex Unit Option 654
Assembly 31: Duplex Unit and Offset Feeder II
hc2m756F
1 2 3 4
1 2 3 4
A
B
C
A
B
C
25
25
25
2
Appendix E. Duplex Unit Option 655
Table 85. Assembly 31: Duplex Unit and Offset Feeder II
Asm–Index Grid
PartNumber Units Description
31– Duplex unit and offset feeder II
–1 A3 90H0716 1 Duplex paper handling assembly (with 31-2∼ 31-24 (same as 30-2)
–2 C2 NP 1 v Duplex frame L
–3 C3 NP 1 v Duplex frame R
–4 B2 NP 1 v Duplex support assembly
–5 B3 NP 1 v Duplex chute
–6 A2 90H3376 1 v Offset assembly (with 31-7∼31-10)
–7 A3 1 v Offset chute assembly
–8 A2 1 v Offset roll
–9 A2 1 v v Offset/Exit roll
–10 A2, A3 4 v v Duplex bearing (in kit P/N 11L5321) (see page 580)
–11 C2 90H3377 1 v v Duplex upper roll
–12 C2 07L0043 v v Duplex lower roll
–13 A1, A2,A3, B1,C1, C4
8 v Duplex bearing (in kit P/N 11L5321) (see page 580)
–14 B1, B2 2 v Pulley gear (in kit P/N 11L5321) (see page 580)
–15 B1, C1 2 v Duplex gear (in kit P/N 11L5321) (see page 580)
–16 B1 90H3378 1 v Sync belt
–17 C4 1 v One-way gear (in kit P/N 06L9998) (see page 580)
–18 C4 1 v Duplex gear D (in kit P/N 06L9998) (see page 580)
Appendix E. Duplex Unit Option 656
Table 85. Assembly 31: Duplex Unit and Offset Feeder II (continued)
Asm–Index Grid
PartNumber Units Description
31– Duplex unit and offset feeder II
–19 C4 1 v Duplex gear C (in kit P/N 06L9998) (see page 580)
–20 B4 3 v Duplex gear B (in kit P/N 06L9998) (see page 580)
–21 B4 1 v Duplex gear A (in kit P/N 06L9998) (see page 580)
–22 A3, A4 2 v Offset gear (in kit P/N 06L9998) (see page 580)
–23 B4 90H3379 1 v Duplex motor
–24 B2 NP 1 v Return chute assembly
–25 C1, C2 NP ? v Clip
Appendix E. Duplex Unit Option 657
Appendix F. Envelope Tray OptionParts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .659
© Copyright IBM Corp. 1998 658
Parts Catalog
1 2 3 4
1 2 3 4
A
B
C
A
B
C
1
25
hc2m509F
Appendix F. Envelope Tray Option 659
Table 86. Assembly 24: Envelope Tray Option
Asm–Index Grid
PartNumber Units Description
24– Envelope Tray Option
–1 A3 90H0721 1 Envelope Tray Option with Cover
–25 C2 90H3467 1 A4 Cassette Cover
Asm–Index numbers not used: 2 to 24
Appendix F. Envelope Tray Option 660
Appendix G. 500-Sheet Paper Tray OptionDiagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .663
11 LOAD <size> IN TRAY n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66316 TRAY n MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66317 TRAY n OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66421 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .664
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665Removal Procedures, Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .666
Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .666Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667
Feed Housing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .669
Feed Housing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .671
Feeder Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .672Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .673Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .673
Feeder PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675
Turn In Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677
Turn Chute Assembly Aux.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678
© Copyright IBM Corp. 1998 661
Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .679Cassette Guide Assembly L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681
Cassette No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684
Cassette Guide Assembly R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .686
Cassette No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .687Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .687Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688
Feed Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .691Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .691Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .692
Electromagnetic Clutch Aux. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .694
Turn Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .696
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697Assembly 20: Optional Tray 2/3 Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697Assembly 21: Optional Tray 2/3 Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Appendix G. 500-Sheet Paper Tray Option 662
Diagnostics
11 LOAD <size> IN TRAY nUse this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.Table 87. 11 LOAD <size> IN TRAY n
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Connection to the tray above the optionv 500 Sheet Feeder (Asm-Index: 20-1, page 697)
v If failing option is in the Tray 2 position: Tray 1 Feeder PWB(Asm-Index: 3-1, page 553)
16 TRAY n MISSINGMeaning : Paper Cassette (Tray 1), Tray 2 and/or Tray 3 are not in place.
Action : Open and close the tray. If you have not installed the tray, do so at this time.Table 88. 16 TRAY n MISSING
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Connection to the tray above the optionv 500 Sheet Feeder (Asm-Index: 20-1, page 697)
v If failing option is in the Tray 2 position: Tray 1 Feeder PWB(Asm-Index: 3-1, page 553)
Appendix G. 500-Sheet Paper Tray Option 663
17 TRAY n OPTION ERRORA 500-sheet option is installed, but is not detected. Ensure that the option is installed correctly.Table 89. 17 TRAY n OPTION ERROR
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Connection to the tray above the optionv 500 Sheet Feeder (Asm-Index: 20-1, page 697)
v If failing option is in the Tray 2 position: Tray 1 Feeder PWB(Asm-Index: 3-1, page 553)
21 PAPER JAMUse this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.Table 90. 21 PAPER JAM
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Connection to the tray above the optionv 500 Sheet Feeder (Asm-Index: 20-1, page 697)
v If failing option is in the Tray 2 position: Tray 1 Feeder PWB(Asm-Index: 3-1, page 553)
Appendix G. 500-Sheet Paper Tray Option 664
Wiring Diagram
HC2M858F
MCU
P/J18
P/J20
FEEDER PWB
FEEDER PWB
FEEDER PWB
P202
P202
P202
P207
P207
P207
P201
P201
P201
FEEDSOLENOID
FEEDSOLENOID
CASSETTENO PAPERSENSOR
CASSETTENO PAPERSENSOR
TURNCLUTCH
TURNCLUTCH
P/J203
P/J203
P/J904
P/J904
P/J205
P/J205
P/J906
P/J906
P/J204
P/J204
P/J206
P/J206
Appendix G. 500-Sheet Paper Tray Option 665
Removal Procedures, Adjustments
Feeder AssemblyAsm-Index: 20-1, page 697.
1
hc2m707F
2
2
Figure 100. Feeder Assembly Removal
Appendix G. 500-Sheet Paper Tray Option 666
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the base engine and the feeder assembly.
3. Remove the two screws (1), using a stabilizer screwdriver, securing the feeder assembly to the baseengine.
4. Lift the base engine to separate it from the feeder assembly.
Replacement1. Rotate the feed roll (Asm-Index: 21-11, page 700) until its rubber surface faces up.
2. Lift the base engine and place it on the feeder assembly positioning the holes in the base engine to thebosses (2) on the feeder assembly.
Attention: Move the base engine horizontally and slowly.3. Using a stabilizer screwdriver, secure the base engine to the feeder assembly using the two screws.
Appendix G. 500-Sheet Paper Tray Option 667
Feed Housing LeftAsm-Index: 20-3, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697).
3. Remove the screw (1) securing the feed housing left (2) to the cassette guide assembly left (Asm-Index:20-16, page 697).
4. Remove the four screws (3) securing the feed housing to the feeder assembly.5. Remove the housing.
hc2m708F
1
2
33
Figure 101. Feed Housing Left Removal
Appendix G. 500-Sheet Paper Tray Option 668
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 669
Feed Housing RightAsm-Index: 20-4, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697).
3. Remove the screw (1) securing the feed housing right to the cassette guide assembly right (2) (Asm-Index:20-23, page 697).
hc2m709F
1
2
3 3
Figure 102. Feed Housing R Removal
Appendix G. 500-Sheet Paper Tray Option 670
4. Remove the four screws (3) securing the feed housing to the feeder assembly.5. Remove the feed housing.
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 671
Feeder Front CoverAsm-Index: 20-5, page 697.
hc2m710F
2 3
3
1
Figure 103. Feeder Front Cover Removal
Appendix G. 500-Sheet Paper Tray Option 672
Removal
1. Switch off printer power and unplug the power cord from the wall.2. Remove the feeder assembly (See page 666).
3. Remove the feed housing left (See page 668).
4. Remove the feed housing right (See page 670).
5. Remove the three screws (1) securing the feeder front cover (2).6. Pressing the two bosses (3) located at the left and right end of the front cover, slide the cover to the front.7. Move the feeder front cover downward to remove it.
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 673
Feeder PWBAsm-Index: 20-11, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Disconnect J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB.
J201
J202
J203
hc2m711F
2
1
1
Figure 104. Feeder PWB Removal
Appendix G. 500-Sheet Paper Tray Option 674
Attention: Do not move the feeder PWB away from the feeder assembly (Asm-Index: 20-1, page 697). Theyare still connected by harnesses.
4. Remove the four screws (1) securing the feeder PWB (2) to the feeder assembly.5. Disconnect J201 of the tray upper harness (Asm-Index: 20-27, page 697) and /J202 of the tray lower 2
harness (Asm-Index: 20-12, page 697) from the feeder PWB.
6. Remove feeder PWB from the feeder assembly.
Replacement1. Reconnect J201 of the tray upper harness and J202 of the tray lower 2 harness to the feeder PWB.
Attention: Do not damage the paper size switch on the feeder PWB during step 2.2. Place the feeder PWB on the feeder assembly.3. Secure the feeder PWB to the feeder assembly using four screws (silver, 6mm).4. Reconnect J203 of the feeder harness to the feeder PWB.5. Route the harnesses so as not to interfere with the function of the paper Size switch.6. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 675
Turn In ChuteAsm-Index: 20-14, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697).
3. Open the turn chute assembly aux (1). (Asm-Index: 20-15, page 697).
4. Flex the left side arm of the turn in chute (2) and remove its hinge hole from the boss on the cassetteguide assembly left (Asm-Index: 20-16, page 697).
5. Remove the turn in chute from the cassette guide assembly right (Asm-Index: 20-23, page 697).
hc2m712F
2
1
Figure 105. Turn In Chute Removal
Appendix G. 500-Sheet Paper Tray Option 676
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 677
Turn Chute Assembly Aux.Asm-Index: 20-15, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the turn in chute (See page 676).
3. Hold the chute assembly open and slide it to the left.4. Lift the rear of the feeder assembly (Asm-Index: 20-1, page 697) and pull the right side of the turn chute
down.
5. Slide the chute to the right and remove it from the feeder assembly.6. Lower the feeder assembly.
hc2m713F1
Figure 106. Turn Chute Assembly Aux. Removal
Appendix G. 500-Sheet Paper Tray Option 678
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 679
Cassette Guide Assembly LAsm-Index: 20-16, page 697.
J203
J206
J204
hc2m714F
2
3
1
1
2
4
Figure 107. Cassette Guide Assembly Left Removal
Appendix G. 500-Sheet Paper Tray Option 680
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the turn in chute (See page 676).
4. Remove the turn chute assembly aux. (See page 678).
5. Disconnect:v J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB (Asm-Index: 20-11,
page 697)
v J204 from the feed solenoid (Asm-Index: 21-18, page 700)
v J206 of the feeder harness connecting to the electromagnetic clutch aux. (Asm-Index: 21-19, page700)
6. Release the clutch side of the feeder harness from the clamp.7. Release the three screws (1) securing the cassette guide assembly L (2) from outside of the frame.8. Remove the screw (3) securing the cassette guide from the front bottom inside the cassette well.9. Using a flat blade screwdriver, push the three hooks (4) at the bottom of the cassette guide assembly L,
up and in, one by one, to release them from the frame.10. Tilt the cassette guide, pulling its bottom edge from the inside of the cassette well.11. Ensure that the three upper hooks of the cassette guide are released from the frame.12. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator
(Asm-Index: 20-26, page 697)
13. Push all harnesses on the cassette guide to free them from the frame.14. Remove the cassette guide from the feeder assembly.
Replacement1. Hold the cassette guide assembly left with the bottom to the right and top to the left so that it will not
interfere with the cassette no paper actuator.
Appendix G. 500-Sheet Paper Tray Option 681
2. Insert the cassette guide into the paper cassette well.3. Insert all connectors on the cassette guide through their openings in the frame.4. Place the upper three hooks of the cassette guide in their respective holes in the frame.5. Pull the feeder harness through the opening in the frame to keep them from being pinched between the
cassette guide and the frame.6. Press the bottom of the cassette guide, tilting it up until the upper and lower hooks lock into position.7. Secure the cassette guide to the feeder assembly using three screws (gold, self tapping, 8mm).8. Insert harnesses to clamps.9. Reconnect:v J203 of the feeder harness to the feeder PWBv J204 to the feed solenoidv J906 of the feeder harness connecting to the electromagnetic clutch aux.
Attention: Route the harnesses so as not to interfere with the gears.10. Ensure the cassette no paper actuator functions properly.11. Reinstall the turn chute assembly aux. (See page 678).
12. Reinstall the turn in chute (See page 676).
13. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 682
Cassette No Paper SensorAsm-Index: 20-21, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the turn in chute (See page 676).
J205
hc2m715F
2
1
Figure 108. Cassette No Paper Sensor Removal
Appendix G. 500-Sheet Paper Tray Option 683
4. Swing the armature (1) of the cassette no paper actuator (Asm-Index: 20-26, page 697) to the rear so thatthe actuator is away from the cassette no paper sensor (2).
5. Open the turn in chute (Asm-Index: 20-14, page 697).
6. Use a small flat blade screwdriver to release the hooks of the no paper sensor, located at the inside of thefeeder assembly (Asm-Index: 20-1, page 697) (work from the rear of the frame), from the feeder assembly.
Attention: Do not move the cassette no paper sensor away since it is connected with a harness.
7. Disconnect J205 from the sensor.8. Remove the sensor.
Replacement1. Swing the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette
no paper sensor.2. Reconnect J205 to the no paper sensor.3. Position the sensor in the opening in the frame, and press the sensor into place until the hooks of the
sensor snap into position.4. Tack the extra length of the harness into the wiring channel of the cassette guide so that the harness does
not interfere with the gears.5. Reinstall the turn in chute (See page 676).
6. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 684
Cassette Guide Assembly RAsm-Index: 20-23, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing right (See page 670).
3. Remove the turn in chute (See page 676).
4. Remove the turn chute assembly aux. (See page 678).
hc2m716F
2
2
1
13
3
Figure 109. Cassette Guide Assembly R Removal
Appendix G. 500-Sheet Paper Tray Option 685
5. Remove the three screws (1) securing the cassette guide assembly R (2) to the feeder assembly(Asm-Index: 20-1, page 697).
6. Using a flat blade screwdriver, push the three hooks (3) at the bottom of the cassette guide assembly R,up and in, one by one, to release them from the frame of the feeder assembly.
7. Tilt the cassette guide, pulling its bottom edge from the inside of the frame.8. Ensure that the three upper hooks of the cassette guide are released from the frame.9. Remove the cassette guide from the feeder assembly.
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 686
Cassette No Paper ActuatorAsm-Index: 20-26, page 697.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the turn in chute (See page 676).
4. Remove the turn chute assembly aux. (See page 678).
5. Remove the cassette guide assembly left (See page 680).
hc3u717F
1
Figure 110. Cassette No Paper Actuator Removal
Appendix G. 500-Sheet Paper Tray Option 687
6. Slide the cassette no paper actuator (1) to the right.7. Release the left end of the no paper actuator from the frame.8. Slide the actuator to the left and remove it from the frame.
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 688
Feed RollAsm-Index: 21-11, page 700.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the turn in chute (See page 676).
4. Remove the turn chute assembly aux. (See page 678).
hc2m718F
4
5
5
4
1
32
Figure 111. Feed Roll Removal
Appendix G. 500-Sheet Paper Tray Option 689
5. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15,page 700) and the frame.
6. Remove the E-ring (3) securing the feed core (Asm-Index: 21-13, page 700) to the feed shaft assembly(4) (Asm-Index: 21-12, page 700).
7. Remove the feed core, the feed core spring (Asm-Index: 21-14, page 700), and the feed gear from thefeed shaft assembly.
8. Rotate the feed shaft assembly until the rubber surface of the feed roll (5) faces to the front.
Attention: Do not damage the cassette no paper actuator (Asm-Index: 20-26, page 697) and the rubber rolls.
9. Hold the feed shaft assembly away from the no paper actuator.10. Press the hook of the feed roll to the front to remove it from the feed shaft.
Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls.1. Align the locating pin of the feed roll with the hole in the feed shaft.2. Press the feed roll to the front to install it onto the shaft of the feed shaft.
Attention: Ensure that the cams are located between the left and right pairs of the feed rolls.3. Reinstall the feed core, the feed core spring, and the feed gear (Asm-Index: 21-15, page 700) from the
feed shaft assembly (Asm-Index: 21-12, page 700).
4. Reinstall the E-ring that secures the feed core to the feed shaft assembly.5. Rotate the feed shaft assembly manually and place the rubber surface of the feed roll upper position.6. Reinstall the feed spring (Asm-Index: 21-17, page 700) on the feed gear and the frame.
7. Reinstall the turn chute assembly aux. (See page 678).
8. Reinstall the turn in chute (See page 676).
9. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 690
Feed SolenoidAsm-Index: 21-18, page 700.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
J204 hc2m720F
1
3
4
2
Figure 112. Feed Solenoid Removal
Appendix G. 500-Sheet Paper Tray Option 691
3. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page700) and the frame.
4. Disconnect J204 of the feed solenoid (3) from the feeder harness (Asm-Index: 20-22, page 697) on thecassette guide assembly L (Asm-Index: 20-16, page 697).
5. Remove the screw (4) securing the feed solenoid to the cassette guide assembly.6. Remove the solenoid from the cassette guide.
Replacement1. Place the feed solenoid in position and secure it using a screw (silver, 6mm).2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly L.Attention: Route the harness so that it does not touch the gears.3. Reinstall the feed spring between the feed gear and the feed solenoid.4. Ensure that the armature of the feed solenoid fixes the feed gear at the upper position, and releases at the
lower position.5. Rotate the feed shaft to place the rubber surface of the feed roll (Asm-Index: 21-11, page 700) up until the
feed gear is released from the feed idler gear (Asm-Index: 21-22, page 700).
6. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 692
Electromagnetic Clutch Aux.Asm-Index: 21-19, page 700.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the feed housing right (See page 670).
4. Remove the turn in chute (See page 676).
J206
hc2m721F
1
2
3
2
4
5
Figure 113. Electromagnetic Clutch Aux. Removal
Appendix G. 500-Sheet Paper Tray Option 693
5. Remove the turn chute assembly aux. (See page 678).
6. Remove the E-ring (1) at the right end of the turn roll assembly (2) (Asm-Index: 21-20, page 700).
7. Remove the right turn bearing (3) (Asm-Index: 21-21, page 700).
8. Disconnect J206 from the electromagnetic clutch aux (4).9. Slide the turn roll assembly (Asm-Index: 21-20, page 700) to the left to remove the left turn bearing from
the frame.
10. Remove the E-ring (5) securing the electromagnetic clutch to the turn roll assembly and remove theclutch from the turn roll.
Replacement1. Place the electromagnetic clutch aux. to the turn roll assembly.2. Reinstall the E-ring to secure the electromagnetic clutch to the turn roll assembly.3. Insert the turn roll assembly from the left and insert the notch of the electromagnetic clutch to the arm of
the frame.4. Insert the left side turn bearing to the frame.5. Install the right side turn bearing to the opening in the frame and secure the bearing using an E-ring.6. Reconnect J206 to the electromagnetic clutch.
Note: Route the harness so that it does not touch the gears.7. Reinstall the turn chute assembly aux. (See page 678).
8. Reinstall the turn in chute (See page 676).
9. Reinstall the feed housing right (See page 670).
10. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 694
Turn Roll AssemblyAsm-Index: 21-20, page 700.
Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).
3. Remove the feed housing right (See page 670).
4. Remove the turn in chute (See page 676).
5. Remove the turn chute assembly aux. (See page 678).
6. Remove the electromagnetic clutch aux. (See page 693).
hc2m722F
1 2
3
54
Figure 114. Turn Roll Assembly Removal
Appendix G. 500-Sheet Paper Tray Option 695
7. Remove the right side E-ring (1) securing the turn bearing (2) (Asm-Index: 21-21, page 700) to the turnroll assembly (3) and remove the right side turn bearing.
8. Remove the two left side E-rings (4) securing the turn bearing (5) to the turn roll assembly and removethe left side turn bearing.
9. Slide the turn roll assembly to the left and release its right end from the frame.10. Slide the turn roll assembly to the right then backward and remove it from the frame.
Replacement
Reverse the Removal procedure.
Appendix G. 500-Sheet Paper Tray Option 696
Parts Catalog
Assembly 20: Optional Tray 2/3 Feeder I
hc2m704F
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Appendix G. 500-Sheet Paper Tray Option 697
Table 91. Assembly 20: Optional Tray 2/3 Feeder I
Asm–Index Grid
PartNumber Units Description
20– Optional tray feeder I
–1 A3 90H0717 1 500 Sheet Feeder w/A4 Cassette (with 20-2∼20-28)
–1 A3 90H3341 1 500 Sheet Feeder w/A3 Cassette (with 20-2∼20-28)
–2 A2 NP 1 v Feeder Frame Assembly (same as 21-2)
–3 A3 NP 1 v Feed housing, left
–4 A4 NP 1 v Feed housing, right
–5 A3 NP 1 v Feeder front housing
–11 B4 90H0771 1 v Feeder PWB
–12 B4 90H0772 1 v Tray lower2 harness
–14 B2 90H0773 1 v Turn in chute
–15 C1 90H3348 1 v Turn chute assembly, auxiliary
–16 B2 90H0775 1 v Cassette guide assembly, left (with 20-17∼20-22, 20-28)
–17 C2 NP 1 v v Cassette guide L
–18 C3 NP 4 v v Size actuator
–19 C3 NP 1 v v Size actuator spring
–20 B2 NP 1 v v Low paper actuator
–21 C3 90H0776 1 v v Cassette no paper sensor
–22 C3 90H0772 1 v v Feeder harness
–28 C3 NP 1 v v Cassette guide cap
–23 B1 90H0777 1 v Cassette guide assembly, right (with 20-24, 20-25)
Appendix G. 500-Sheet Paper Tray Option 698
Table 91. Assembly 20: Optional Tray 2/3 Feeder I (continued)
Asm–Index Grid
PartNumber Units Description
20– Optional tray feeder I
–24 B1 NP 1 v v Cassette guide R
–25 B1 NP 1 v v Cassette stopper spring
–26 B2 90H0778 1 v Cassette no paper actuator
–27 B4 90H3352 1 v Tray upper harness
Asm–Index numbers not used: 6 to 10, 13
Appendix G. 500-Sheet Paper Tray Option 699
Assembly 21: Optional Tray 2/3 Feeder II
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m705F
Appendix G. 500-Sheet Paper Tray Option 700
Table 92. Assembly 21: Optional Tray Feeder II
Asm–Index Grid
PartNumber Units Description
21– Optional tray feeder II
–1 A2 90H0717 1 500 Sheet Feeder w/A4 Cassette (with 21-2∼21-24)
–1 A2 90H3341 1 500 Sheet Feeder w/A3 Cassette (with 21-2∼21-24)
–2 A2 NP 1 v Feeder frame assembly
–3 B2 NP 1 v Feeder connector
–11 B2, C2 4 v Feed roll (in feed roll kit 90H0779)
–12 C2 90H0780 1 v Feed shaft assembly
– 90H0781 1 v Feed core assembly kit (with 21-13∼15, 21-17)
–13 B4 1 v v Feed core (in kit P/N 90H0781) (see page 580)
–14 B4 1 v v Feed core spring (in kit P/N 90H0781) (see page 580)
–15 B4 1 v v Feed gear (in kit P/N 90H0781) (see page 580)
–17 B4 1 v v Feed spring (in kit P/N 90H0781) (see page 580)
–16 A1, B3 2 v Feed bearing (in kit P/N 06L9997) (see page 580)
–18 A4 90H0782 v Feed solenoid
–19 C4 90H3355 1 v Electromagnetic clutch, auxiliary
–20 C2 90H0784 1 v Turn roll assembly
–21 A1 2 v Turn bearing (in kit P/N 90H0786) (see page 580)
–22 B3 1 v Feed idler gear (in kit P/N 90H3384) (see page 580)
–23 B3, C3 2 v Out idler gear (in kit P/N 90H3384) (see page 580)
Appendix G. 500-Sheet Paper Tray Option 701
Table 92. Assembly 21: Optional Tray Feeder II (continued)
Asm–Index Grid
PartNumber Units Description
21– Optional tray feeder II
–24 A4 1 v In idler gear (in kit P/N 90H3384) (see page 580)
Asm–Index numbers not used: 4 to 10
Appendix G. 500-Sheet Paper Tray Option 702
Appendix H. 2000-Sheet Input Drawer OptionImportant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .707Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708
03 2000-SHEET COVER OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70815 TRAY n NOT READY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70917 2000 SHEET INPUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71026 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .716Removal Procedures, Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
2000-Sheet Input Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718
Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .719Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720
HCF Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .723Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724
Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726
Lift Up Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728
Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .729
© Copyright IBM Corp. 1998 703
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .730Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .730
Near Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
Lower Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .733Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .733Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734
Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736
Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .738
Paper Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .739Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740
Transport Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742
Right Hand Cover Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744
Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .745Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746
Feed Roller Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .747Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748
Upper Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750
Appendix H. 2000-Sheet Input Drawer Option 704
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .751
Paper Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .752Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .752Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .754Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .754Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .755
Tray Set Sensor 1,2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .757
Left Hand Cover Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759
Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .760Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .760Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .761
LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .763
Rear Cover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .764Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765
Transport Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .766Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767
Flat Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .769
Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .770
Appendix H. 2000-Sheet Input Drawer Option 705
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .770Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .771
Connector Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .772Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .773Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .773
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774Assembly 40: 2000-Sheet Input Drawer I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774Assembly 41: 2000-Sheet Input Drawer Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .776Assembly 42: 2000-Sheet Input Drawer II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .778
Appendix H. 2000-Sheet Input Drawer Option 706
Important InformationNote: When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power
switches. One cord connects the option to the wall outlet, and the other connects the option to theprinter. AC power is present on both machines even when both power switches are turned off.
Appendix H. 2000-Sheet Input Drawer Option 707
Diagnostics
03 2000-SHEET COVER OPENOne of the two interlock switches on the rear cover of the HCF is not activated.
Note: This error can occur if the cover is opened, but the jammed paper is not removed.
Switch the power off and then on. If 26 PAPER JAM occurs, go to “26 PAPER JAM” on page 711.
Use “D21 SENSOR TEST” on page 261 to isolate help isolate the problem.Table 93. 03 2000-SHEET COVER OPEN
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Right Cover Open Switch (Asm-Index: 42-9, page 778), see page 743for the removal procedure.
v Left Cover Open Switch (Asm-Index: 42-20, page 778), see page 758for the removal procedure.
v HCF Rear Cover (Asm-Index: 42-2, page 778), see page 764 for theremoval procedure.
v Flat harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.
v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for theremoval procedure.
Appendix H. 2000-Sheet Input Drawer Option 708
15 TRAY n NOT READYThe paper tray for the 2000-Sheet Input Drawer (High Capacity Feeder; HCF) is open, or the ″elevator″ for thestack of paper is in motion. If this error displays, wait 2 minutes. If it becomes a 26 PAPER JAM, go to “26PAPER JAM” on page 711.Table 94. 15 TRAY n NOT READY
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v Obstruction from Right Casterv Tray Set Sensor 1 (Asm-Index: 42-18, page 778), see page 756 for the
removal procedure.
v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.
v Harness (Asm-Index: 41-16, page 776), see page 737 for the removalprocedure.
v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for theremoval procedure.
Appendix H. 2000-Sheet Input Drawer Option 709
17 2000 SHEET INPUT ERRORThe 2000-Sheet Input Option (High Capacity Feeder; HCF) is installed, but is not detected. Ensure that theoption is installed correctly.Table 95. 17 2000 SHEET INPUT ERROR
Step Actions and Questions Yes No
SUSPECT COMPONENTS
v HCF power problem (The HCF should be plugged to the wall. Theprinter should be plugged to the HCF. Both power switches must beon).
v HCF LVPS (Asm-Index: 42-25, page 778)), see page 762 for theremoval procedure.
v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.
v Harness (Asm-Index: 41-16, page 776), see page 737 for the removalprocedure.
Appendix H. 2000-Sheet Input Drawer Option 710
26 PAPER JAMThere is a jam condition at the 2000-Sheet Input Option (High Capacity Feeder, HCF). This error is posted forseveral different conditions:v Paper never arrived at the HCF exit sensor actuator, located on the back door (chute) of the HCF.v Paper arrived at the the HCF exit sensor, but it never deactuated.v HCF tray (″elevator″) does not travel up or down correctly. (A 15 TRAY n NOT READ message will probably
display first and then turn into a 26 PAPER JAM message.)
Notes:1. When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches.
One cord connects the option to the wall outlet, and the other connects the option to the printer. ACpower is present on both machines even when both power switches are turned off.
2. If HCF option is installed directly beneath the printer, it is ″Tray 2″. If a 500-sheet option is installedbeneath the printer, it is Tray 2 and the HCF is Tray 3. In this MAP, generally the term Tray n is used.
3. It is normal for the HCF tray (″elevator″) to move after the printer power is turned on. It will move the trayup toward the top position where a sensor checks for a stack of paper. If no paper is detected, the traymoves all the way down (the position needed for paper loading). While the tray is moving, the operatorpanel may display a 15 2000-SHEET INPUT NOT READY message.
4. When the HCF tray is opened , the 15 2000-SHEET INPUT NOT READY message will display. Theelevator should move down until it reaches its lowest position. After the tray is closed, the elevator shouldmove up until the top of the stack of paper reaches the top position. (If there is no paper, it will move backdown.)
SUSPECT COMPONENTS1. HCF pick problem (paper never leaves HCF tray, but paper loading is OK):v Feed Roller (Asm-Index: 41-14, page 776)
v Feed Motor (Asm-Index: 42-28, page 778)
Appendix H. 2000-Sheet Input Drawer Option 711
v Flat Harness (Asm-Index: 42-29, page 778)
2. HCF transport problem (paper gets picked and starts to leave the tray, but does not continue into paperpath):v Transport Motor (Asm-Index: 42-21, page 778)
v Transport Belt (Asm-Index: 42-22, page 778)
v Transport Gear (Asm-Index: 42-23, page 778)
v Transport Roll (Asm-Index: 42-7, page 778) - test with “D68 HCF MOTOR (HCF Transport Motor)” onpage 291
v Flat Harness (Asm-Index: 42-7, page 778)
v Paper Chute (Asm-Index: 42-5, page 778)
3. HCF elevator problem:v Test with “D44 HCF UP (Tray Lifts)” on page 273 & “D45 HCF DOWN (Tray Lowers)” on page 275
v Lift up motor (Asm-Index: 41-10, page 776)
v Lower position sensor (Asm-Index: 41-12, page 776)
v Upper limit sensor (Asm-Index: 42-11, page 778), test with “D21 SENSOR TEST” on page 261
v Paper level sensor (Asm-Index: 42-2, page 778)
4. Sensor Problems that cause false 26 errors after power is turned on:v HCF exit sensor (42-10)- test with “D21 SENSOR TEST” on page 261
v Tray set #2 sensor (42-19) - 15 message will occur first - test with “D21 SENSOR TEST” on page 261
5. Sensor Problems that cause 26 during printing from HCF:v HCF exit sensor actuator (Asm-Index: 42-5, page 778)
v HCF exit sensor (42-10) - test with “D21 SENSOR TEST” on page 261
v No paper sensor (Asm-Index: 42-28, page 778) - test with “D21 SENSOR TEST” on page 261
Appendix H. 2000-Sheet Input Drawer Option 712
v Paper level sensor (Asm-Index: 42-2, page 778)
Note: The HCF near empty sensor is not used
6. General FRUs for 26 Jam (valid in all of the lists above)v HCF LVPS (Asm-Index: 42-25, page 778)
v Cables (check all connections at HCF LVPS)v HCF optionv MCU
Table 96. 26 PAPER JAM
Step Actions and Questions Yes No
1.
Switch on the printer power and the HCF power. Wait until the printer isready or an error displays.
Is there an error?
If the initial error is26, go to step 3. Ifthe initial error is15, go to step 2.
Go to step 4
2.
Wait 2 minutes to see if the 15 error turns into a 26 PAPER JAM.
Does a 26 PAPER JAM display?
Go to step 4 For other errors,go to “Chapter 1.Getting Started”on page 25.
3.
Open the rear door of the HCF.
Is there any paper or paper scraps in the path?
Remove thepaper. Open andclose the topcover to reset theerror. Go to step4.
False 26 errors.Go to SuspectComponents list 4,then 3 and 6.
Appendix H. 2000-Sheet Input Drawer Option 713
Table 96. 26 PAPER JAM (continued)
Step Actions and Questions Yes No
4.
ELEVATOR FUNCTION:
Put paper in the HCF tray. The elevator should go down when you open thetray and then go up when you close the tray. A 15 message is normal duringtray motion, but it should not turn into a 26.
Does the Elevator function correctly?
Go to step 5 Go to SuspectComponents, lists3 and 6.
5.
Print from the HCF:a. Set PAPER MENU/SOURCE=Tray2 or Tray3.b. Ensure that there is paper in the HCF.c. Go OFFLINE.d. Use TEST MENU/CONFIG PAGE.
Does the CONFIG page print correctly?
Go to step 6 For 26 PAPERJAMs, go to step7. For otherproblems, go toStart of Call.
6.
a. Remove the paper from the HCF.b. Set PAPER MENU/TRAY SWITCH=off.c. Try to print another CONFIG page.
Does an 11 LOAD message occur?
Unknown problem.If the problempersists, install anew HCF option.
If a 26 erroroccurs, install anew HCF nopaper sensor(Asm-Index:42-28, page 778).
7.
Open the rear door of the HCF.
Did the paper start to leave the HCF tray?
Go to step 8 Pick problem. Goto SuspectComponents, lists1 and 6.
Appendix H. 2000-Sheet Input Drawer Option 714
Table 96. 26 PAPER JAM (continued)
Step Actions and Questions Yes No
8.
Run D68 (see “D68 HCF MOTOR (HCF Transport Motor)” on page 291). Youwill have to override the HCF rear cover switches to watch the transport rollmove.
Does the Transport Roll move?
Go to step 9 Transportproblem. Go toSuspectComponents, lists2 and 6.
9.
You have a problem caused by one of the following:v HCF exit actuator (Asm-Index: 42-5, page 778)
v HCF exit sensor (42-10) - test with “D21 SENSOR TEST” on page 261
v Paper path obstruction
10.End of Diagnostic
Appendix H. 2000-Sheet Input Drawer Option 715
Wiring Diagram
RIGHT HAND COVEROPEN SWITCH
LEFT HAND COVEROPEN SWITCH
TRANSPORT MOTOR
SENSOR
TRAY SET SENSOR 1
PAPER LEVEL SENSOR
ENCODER
FEEDMOTORCONTROL
NO PAPER SENSOR
UPPER LIMIT SENSOR
TRAY SET SENSOR 2
SIZE SENSOR
NEAR EMPTY SENSOR
LOWER POSITION SENSOR
LIFT UP MOTOR
P/J:M1
P/J:S2
P/J:S7
P/J:S11
P/J:S3
P/J:P1
P/J:S1
P/J:XS4
P/J:P2
P/J:S10
P/J:S6
P/J:S12
P/J:S9
P/J:M2
P/J:S8
LIFT UPMOTORCONTROL
CPU
SG
P/J:XS3RXDTXDSGSG
FEEDER CHECK
BaseEngine
or
2ND TRAY
(+)( - )
13
13
13
21
13
321
54
123
123
1234
12
123
12
12
GNDGND
FG
DC21
DC22
DC22
SWHD
SGSWPL(TTL)
SGSWPSZ(TTL)
DC21SWHU1
SWHU1SWHU2
+5VDC
LSPE(TTL)
SG
DC11DC12
+5VDC
ENCOD(TTL)
SG
+5VDC
LSPL(TTL)
SG
SWCPR(TTL)
SG
+5VDC
LSPEX(TTL)
SG
SM1
SM2
SM3
SM4
SWDO1(TTL)
SWDO(TTL)
SWDO1(TTL)
SG
FEED MOTOR
141612139
12345
P/J:XS110912
56
78
34
P/J:XS2
1211
2526
12
345
678
222324
910
131415
18192021
1617
2728
TRANSPORTMOTORCONTROL
MAIN SWITCHAC to DC
SERVICE CONNECT
AC INLET
LVPS
M
M
M
This is an internal wiring of the FEED ROLLER KIT,therefore the P/J No. and Pin No. are omitted.hc2m089F
Appendix H. 2000-Sheet Input Drawer Option 716
Removal Procedures, Adjustments
2000-Sheet Input DrawerAsm: 40, page 774.
[ 1 ]
hc2m072F
1
Figure 115. 2000-Sheet Input Drawer Removal
Appendix H. 2000-Sheet Input Drawer Option 717
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Paper Cassette from the Base Engine or Option Tray.4. Remove the two screws (1) that lock the HCF to the Base Engine.
5. Lift the Base Engine to separate the Base Engine and the HCF. Remove the HCF.
Replacement
Attention: In the step below, match the HCF positioning boss with the Base Engine positioning boss.Gently place the main unit on the HCF; make sure it goes on straight.
1. Lift the Base Engine and install it on the HCF.2. Lock the Base Engine and the HCF with the two screws.3. Install the paper cassette, if Base Engine or Option Tray is installed.
Appendix H. 2000-Sheet Input Drawer Option 718
FootAsm-Index: 40-3, page 774.
hc2m024F1
2
2 1
Figure 116. Foot Removal
Appendix H. 2000-Sheet Input Drawer Option 719
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the four screws (1) that lock the Foot (2). Remove the Foot.
Replacement
Reverse the Removal procedure.
Appendix H. 2000-Sheet Input Drawer Option 720
HCF Tray AssemblyAsm-Index: 41-1, page 776.
hc2m023F
[ 1 ][ 2 ]
[ 3 ] [ 4 ]
1
2
1
Figure 117. HCF Tray Assembly Removal
Appendix H. 2000-Sheet Input Drawer Option 721
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Disconnect the P/J:XS1 (See 1 in the figure).Attention: In the next step, carefully sqeeze the release hooks on the clamp from the backside. The hooksbreak easily.5. Remove the harness clamp (See 2 in the figure).6. Remove the two screws (1) securing the HCF Tray Assembly (2).7. Remove the hooks (See 3 in the figure) on the front side of the slide rails. (The hooks lock the HCF Tray
Assembly.)Attention: When you remove the HCF Tray Assembly in the step below, support the Tray (rear) so that it willnot fall.8. Remove the hooks (See 4 in the figure) on the rear side of the slide rails. (The hooks lock the HCF Tray
Assembly.)
Replacement1. Install the rear hooks on the HCF Tray Assembly.2. Install the front hooks on the HCF Tray Assembly.3. Lock the HCF Tray Assembly with the two screws .4. Install the harness clamp.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.5. Connect the P/J:XS1.6. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 722
Side PlateAsm-Index: 41-3 and 41-13, page 776.
hc2m025F
1
1
Figure 118. Side Plate Removal
Appendix H. 2000-Sheet Input Drawer Option 723
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Turn the keys that lock the Side Plates (1).5. Remove the Side Plates.
Replacement
Reverse the Removal procedure.
Appendix H. 2000-Sheet Input Drawer Option 724
Front CoverAsm-Index: 41-7, page 776.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the four screws (1) that lock the Front Cover (2).5. Remove the Front Cover.
hc2m026F
2
1
1
Figure 119. Front Cover Removal
Appendix H. 2000-Sheet Input Drawer Option 725
Replacement
Attention: When you install the Front Cover in the step below, make sure that all the hooks are in place.1. Install the Front Cover.2. Lock the Front Cover with the four screws.3. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 726
Lift Up MotorAsm-Index: 41-10, page 776.
-
+
P/J:M1-(-)
P/J:M1-(+)
Black
Red
[ 1 ][ 2 ]
hc2m027F1
2
3
Figure 120. Lift Up Motor Removal
Appendix H. 2000-Sheet Input Drawer Option 727
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Front Cover (See page 725).
5. Disconnect the P/J :M1.Attention: When you remove the Lift Up Motor in the steps below, place an object or your hand on theBottom Plate to prevent it from springing up.6. Remove the two screws that lock the Lift Up Motor. You can also remove the motor by just loosening
them.7. Remove the E-ring.8. Remove the Lift Up Motor.
Replacement1. Install the Lift Up Motor.2. Install the E-ring.Attention: When you lock the Lift Up Motor in the step below, the tube washer should not overlap thepositioning post. (See 1 in the figure.)3. Lock the Lift Up Motor with the two screws.Attention: In the step below, check the cable color when connecting the P/J. If the P/J is not connectedproperly, the system malfunctions or may be damaged. (See 2 in the figure). When you connect the P/J in thestep below, make sure that the harness or other components are not touching the motor’s rotatingcomponents.If they come in contact with the rotating components, they will be damaged.4. Connect the P/J :M1.5. Install the Front Cover (See page 725).
6. Insert the HCF Tray Assembly into HCF.
Appendix H. 2000-Sheet Input Drawer Option 728
Bottom PlateAsm-Index: 41-2, page 776.
[ 1 ]
[ 2 ]
[ 3 ]
hc2m046F
1
1
1
Figure 121. Bottom Plate Removal
Appendix H. 2000-Sheet Input Drawer Option 729
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Plates (See page 723).
5. Remove the locks (see 1 in the figure) on the Bottom Plate (1) (use a screwdriver if necessary).6. Lift the back side of the Bottom Plate, remove the Bottom Plate (See 2 in the figure).
Replacement
Attention: When you install the Bottom Plate in the step below, make sure that the rear roller in the LiftUp mechanism has been properly installed on the roller guide of the Bottom Plate (See 3 in the figure).
1. Install the Bottom Plate.2. Lock the Bottom Plate (use a screwdriver if necessary).3. Install the Side Plates (See page 723).
4. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 730
Near Empty SensorAsm-Index: 41-11, page 776.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.
hc2m028F
1
Figure 122. Near Empty Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 731
4. Remove the Front Cover (See page 725).
5. Remove the Near Empty Sensor.6. Disconnect the P/J:S1.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.
1. Connect the P/J:S1.Attention: In the step below, install the Near Empty Sensor to the correct direction, otherwise the sensor pinsmay be damaged.2. Install the Near Empty Sensor (1).3. Install the Front Cover (See page 725).
4. Insert the HCF Tray Assembly.
Appendix H. 2000-Sheet Input Drawer Option 732
Lower Position SensorAsm-Index: 41-12, page 776.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Panels (See page 723).
hc2m029F
1
Figure 123. Lower Position Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 733
5. Remove the Bottom Plate (See page 729).
6. Remove the Lower Position Sensor (1).7. Disconnect the P/J:S2.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.
1. Connect the P/J:S2.Attention: In the step below, install the Lower Position Sensor to the correct direction, otherwise the sensorpins may be damaged.2. Install the Lower Position Sensor.3. Install the Bottom Plate (See page 729).
4. Install the Side Plates (See page 723).
5. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 734
Size SensorAsm-Index: 41-15, page 776.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Plates (See page 723).
hc2m073F
1
Figure 124. Size Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 735
5. Remove the Bottom Plates (See page 729).
6. Remove the Size Sensor (1).7. Disconnect the P/J:S3.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.
1. Connect the P/J:S3.Attention: In the step below, install the Size Sensor to the correct direction, otherwise the sensor pins maybe damaged.2. Install the Size Sensor.3. Install the Bottom Plate (See page 729).
4. Install the Side Plates (See page 723).
5. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 736
HarnessAsm-Index: 41-16, page 776.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Disconnect the P/J:XS1 (See 1 in the figure).5. Remove the Front Cover (See page 725).
6. Remove the Bottom Plate (See page 729).
7. Remove the Holder (See 2 and 3 in the figure).8. Remove the cable clamp.
hc2m078F
White
Green
Gray Blue
Brown
Orange
-
+
Black
Red
[ 1 ][ 3 ]
[ 4 ] [ 7 ]
[ 6 ]
[ 5 ]
[ 8 ]
[ 2 ]
1
Figure 125. Harness Removal
Appendix H. 2000-Sheet Input Drawer Option 737
9. Disconnect the P/Js that are connected to the following: Near Empty Sensor, Size Sensor , LowerPosition Sensor and Lift Up Motor.
10. Remove the Harness (1).
Replacement1. Install the Harness.Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.2. Connect the P/Js to the following: Near Empty Sensor, Size Sensor, Lower Position Sensor and Lift Up
Motor.3. Install the cable clamp.4. Install the Holder.5. Install the Bottom Plate (See page 729).
6. Install the Front Cover (See page 725).Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.
7. Connect the P/J:XS1.8. Insert the HCF Tray Assembly into the HCF.
Appendix H. 2000-Sheet Input Drawer Option 738
Paper ChuteAsm-Index: 42-5, page 778.
[ 1 ]
hc2m032F
2
1
Figure 126. Paper Chute Removal
Appendix H. 2000-Sheet Input Drawer Option 739
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Rear Cover Kit (1) from the HCF (See page 764).
4. Remove the Paper Chute (2) from the Rear Cover Kit.
Replacement
Attention: When you install the Paper Chute in the step below, make sure that the four springs areinstalled properly, otherwise the system will malfunction (See 1 in the figure).
1. Install the Paper Chute to the Rear Cover Kit.2. Install the Rear Cover Kit to the HCF (See page 764).
Appendix H. 2000-Sheet Input Drawer Option 740
Transport Unit AssemblyAsm-Index: 42-7 to 42-24, and 42-29, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.
hc2m045F
2
1
Figure 127. Transport Unit Assembly Removal
Appendix H. 2000-Sheet Input Drawer Option 741
3. Remove the Rear Cover Kit from the HCF (See page 764).
4. Roll out the HCF Tray Assembly from the HCF.5. Disconnect the P/J:XS2 from LVPS.Attention: When you remove the screws in the step below, support the Transport Unit Assembly firmly withyour hand so that it will not fall.6. Remove the two screws (1) securing the Transport Unit Assembly (2).7. Remove the Transport Unit Assembly.
Replacement1. Install the Transport Unit Assembly.2. Secure the Transport Unit Assembly with the two screws.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.3. Connect the P/J:XS2 to LVPS.4. Insert the HCF Tray Assembly into the HCF.5. Install the Rear Cover Kit to the HCF (See page 764).
Appendix H. 2000-Sheet Input Drawer Option 742
Right Hand Cover Open SwitchAsm-Index: 42-9, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.
hc2m041F
1
Figure 128. Right Hand Cover Open Switch Removal
Appendix H. 2000-Sheet Input Drawer Option 743
3. Remove the Transport Unit Assembly (See page 741).
4. Remove the Right Hand Cover Open Switch (1).5. Disconnect the P/J:S12.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.
1. Connect the P/J:S12.Attention: In the step below, install the Right Hand Cover Open Switch in the correct direction, otherwise theswitch pins may be damaged.2. Install the Right Hand Cover Open Switch.3. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 744
Exit SensorAsm-Index: 42-10, page 778.
hc2m035F
1
Figure 129. Exit Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 745
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Disconnect the P/J:S8.5. Remove the Exit Sensor (1).
Replacement1. Install the Exit Sensor.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:S8.3. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 746
Feed Roller KitAsm-Index: 42-28, page 778.
[ 1 ]
[ 3 ]
[ 2 ]
hc2m030F5
6
2
4
21
3
Figure 130. Feed Roller Kit Removal
Appendix H. 2000-Sheet Input Drawer Option 747
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Disconnect the P/J:P1 and P/J:P2 connected to the Feed Roller Kit Harness (1).5. Remove the harness clamp securing the Feed Roller Kit Harness .6. Remove the two Feed Roller Kit Springs (2).7. Remove the hooks (3) (See 1 in the figure) securing the Feed Roller Kit (4).8. Remove the Right Hand Feed Roller Bracket (5) and the Left Hand Feed Roller Bracket (6) (See 2 in the
figure)that lock the Feed Roller Kit.9. Remove the Feed Roller Kit.
Replacement
Appendix H. 2000-Sheet Input Drawer Option 748
Attention: In the step below, check that the Feed Roller Kit properly pushes the Paper Level SensorActuator (See 3 in the figure).
1. Install the Feed Roller Kit.2. Fix the Feed Roller Kit on the Right Hand Feed Roller Bracket and Left Hand Feed Roller Bracket and
attach it to the frame in the Transport Unit Assembly.3. Secure the Feed Roller Kit using the hooks.4. Install the two Feed Roller Kit Springs.5. Secure the Feed Roller Kit Harness with the harness clamp.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.6. Connect the P/J:P1 and P/J:P2.7. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 749
Upper Limit SensorAsm-Index: 42-11, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Remove the Feed Roller Kit (See page 747).
5. Remove the Upper Limit Sensor (1).
hc2m036F
1
Figure 131. Upper Limit Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 750
6. Disconnect the P/J:S11.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.
1. Connect the P/J:S11.Attention: In the step below, install the Upper Limit Sensor to the correct direction, otherwise the sensor pinsmay be damaged.2. Install the Upper Limit Sensor.3. Install the Feed Roller Kit (See page 747).
4. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 751
Paper Level SensorAsm-Index: 42-12, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Remove the Feed Roller Kit (See page 747).
5. Disconnect the P/J:10.
hc2m037F1
Figure 132. Paper Level Sensor Removal
Appendix H. 2000-Sheet Input Drawer Option 752
6. Remove the Paper Level Sensor (1).
Replacement1. Install the Paper Level Sensor.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:10.3. Install the Feed Roller Kit (See page 747).
4. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 753
Feed RollerAsm-Index: 42-14, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Open the Rear Cover Kit.4. Remove the Feed Roller (1).
hc2m038F
1
Figure 133. Feed Roller Removal
Appendix H. 2000-Sheet Input Drawer Option 754
Replacement
Reverse the Removal procedure.
Appendix H. 2000-Sheet Input Drawer Option 755
Tray Set Sensor 1,2Asm-Index: 42-18 and 42-19, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Remove the Tray Set Sensors 1 (1) and 2 (2).
hc2m039F
21
Figure 134. Tray Set Sensor 1,2 Removal
Appendix H. 2000-Sheet Input Drawer Option 756
Note: Label the wires before removing them in the next step.5. Disconnect the P/J:S6 and P/J :S7.
Replacement
Attention: In the step below, connect the P/J’s as labeled, otherwise the system malfunctions.1. Connect the P/J:S6 and P/J :S7.Attention: In the step below, install the Tray Set Sensors 1 and 2 in the correct direction, otherwise thesensor pins may be damaged.2. Install the Tray Set Sensors 1 and 2.3. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 757
Left Hand Cover Open SwitchAsm-Index: 42-20, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.
hc2m040F1
Figure 135. Left Hand Cover Open Switch Removal
Appendix H. 2000-Sheet Input Drawer Option 758
3. Remove the Transport Unit Assembly (See page 741).
4. Remove the Left Hand Cover Open Switch (1).5. Disconnect the P/J:S9.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.1. Connect the P/J:S9.Attention: In the step below, install the Left Hand Cover Open Switch in the correct direction, otherwise theswitch pins may be damaged.2. Install the Left Hand Cover Open Switch.3. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 759
Transport MotorAsm-Index: 42-21, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
hc2m042F
2
1
Figure 136. Transport Motor Removal
Appendix H. 2000-Sheet Input Drawer Option 760
4. Disconnect the P/J:M2.5. Remove the two screws (1) securing the Transport Motor (2).6. Remove the Transport Motor.
Replacement1. Secure the Transport Motor with the two screws .Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:M2.3. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 761
LVPSAsm-Index: 42-25, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the HCF Tray Assembly (See page 721).
hc2m043F1
3
2
Figure 137. LVPS Removal
Appendix H. 2000-Sheet Input Drawer Option 762
4. Disconnect the P/J:XS1, XS2, XS3.5. Remove the screw (1) securing the ground wire coming from LVPS (2).6. Remove the four screws (3) securing the LVPS to the HCF.7. Remove LVPS.
Replacement1. Secure LVPS to HCF with the four screws .2. Secure LVPS ground wire with the screw.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.3. Connect the P/J:XS1, XS2, XS3.4. Install the HCF Tray Assembly (See page 721).
Appendix H. 2000-Sheet Input Drawer Option 763
Rear Cover KitAsm-Index: 42-26, page 778.
hc2m031F
1 2
Figure 138. Rear Cover Kit Removal
Appendix H. 2000-Sheet Input Drawer Option 764
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Open the Rear Cover Kit (1).
Note: In the step below, open the Rear Cover Kit halfway for easy removal.4. Remove the Screw (2) holding the strap.5. Remove the Rear Cover Kit.
Replacement
Reverse the Removal procedure.
Appendix H. 2000-Sheet Input Drawer Option 765
Transport Roll KitAsm-Index: 42-27, page 778.
[ 1 ]
hc2m033F
11
32
5
4
Figure 139. Transport Roll Kit Removal
Appendix H. 2000-Sheet Input Drawer Option 766
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
4. Remove the two E-rings (1).5. Remove the Gear (2).6. Remove the Left Hand Lock (3).7. Remove the Right Hand Lock (4).8. Remove the Transport Roll (5).
Replacement1. Install the Transport Roll.2. Install the Right Hand Lock.3. Install the Left Hand Lock.Attention: In the step below, install the Gear so that the belt guard (See 1 in the figure) is to the outside.4. Install the Gear.5. Install the five E-rings.6. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 767
Flat HarnessAsm-Index: 42-29, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
hc2m044F
1
Figure 140. Flat Harness Removal
Appendix H. 2000-Sheet Input Drawer Option 768
4. Disconnect all P/Js connected to the Flat Harness.5. Remove all harness clamps securing the Flat Harness.6. Disconnect the Flat Harness (1).
Replacement1. Connect the Flat Harness.2. Secure Flat Harness with the harness clamps.Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system willmalfanction.3. Connect the P/Js.4. Install the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 769
BeltAsm-Index: 42-22, page 778.
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).
hc2m079F
1
Figure 141. Belt Removal
Appendix H. 2000-Sheet Input Drawer Option 770
4. Remove the Transport Motor (See page 760).
5. Remove the Belt (1).
Replacement
Reverse the Removal procedure.
Appendix H. 2000-Sheet Input Drawer Option 771
Connector KitAsm-Index: 42-32, page 778.
[2]
[1]
hc2m080F
1
2
Figure 142. Connector Kit Removal
Appendix H. 2000-Sheet Input Drawer Option 772
Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the HCF from the Base Engine (See page 717).
4. Disconnect the P/J:XS3 (See 1 in the figure).5. Remove the two screws (1) securing the Connector Kit (2).6. Disconnect the Connector Kit.
Replacement1. Connect the Connector Kit.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:XS3.3. Secure the Connector Kit with the two screws.4. Install the Base Engine.
Appendix H. 2000-Sheet Input Drawer Option 773
Parts Catalog
Assembly 40: 2000-Sheet Input Drawer I
1 (with 1A-18)
3
4
4
3
4
45
11
11
14
15
2. (PL42.1)10
10
12
1216
17
hc2m020F
18 (with 16,17)
19 (with 4,5)
1A (PL41.1)
13
13
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Appendix H. 2000-Sheet Input Drawer Option 774
Table 97. Assembly 40: 2000-Sheet Input Drawer I
Asm–Index Grid
PartNumber Units Description
40– 90H0720 High-capacity feeder I
–1 A3 NP 1 v High-capacity tray assembly (with 40-2∼40-18)
–1A A2 NP 1 v High-capacity input drawer tray (same as 41-1)
–2 A4 NP 1 v v High-capacity feeder assembly (same as 42-1)
–3 B2, C3 90H3469 2 v v Foot
–6 NP v v Wingnut
–7 NP v v Disk
–8 NP v v Disk
–10 A3, A4 11L5342 2 v v HCF Screw
–11 B4 90H3472 2 v v Castor, Non-Locking
–12 B2, B3 11L5343 2 v v HCF Locking Castor
–13 B1 11L5357 2 v v Drawer Castor
–14 and–15
A2, A3 11L5344 1 v v E-ring and Clip
–18 C1 90H3471 1 v v Rails (with 40-16 and 40-17)
–16 B2 NP 1 v v v Rail
–17 B1 NP 1 v v v Rail
–19 C1 90H3470 1 v Hex Screw (with 40-4 and 40-5)
–4 B3, C3,C4
NP 4 v v Hex screw
–5 C2 NP 1 v v Hex key
Appendix H. 2000-Sheet Input Drawer Option 775
Assembly 41: 2000-Sheet Input Drawer Tray
1 2 3 4
1 2 3 4
A
B
C
A
B
C
hc2m021F
1 (with 2-18)19 (with 4,5)
2
134
4
35
5
14
1414
6
141215
18
17
17
16
18
7
89
9
10
11
Appendix H. 2000-Sheet Input Drawer Option 776
Table 98. Assembly 41: 2000-Sheet Input Drawer Tray
Asm–Index Grid
PartNumber Units Description
41– 90H0720 High-capacity feeder tray
–1 A4 NP 1 v High-capacity input drawer tray (with 41-2∼41-18)
–2 A4 NP 1 v v Bottom plate
–3 B4 NP 1 v v Right hand side plate
–6 B4 NP 1 v v Tray frame assembly
–7 B1 90H3474 1 v v Front cover
–8 C2 NP 1 v v Bearing
–9 C2 NP 2 v v Ring
–10 C2 90H3475 1 v v Elevator motor
–11 C2 90H3476 1 v v Paper low sensor
–12 B3 90H3477 1 v v Lower position sensor
–13 A3 NP 1 v v Left-hand side plate
–14 B3 11L5346 4 v v HCF Centering Format
–15 B2 11L5347 1 v v HCF Size Sensor
–16 A2 11L5348 1 v v HCF Harness
–17 A1, B2 11L5349 2 v v HCF Holder
–18 B1, B2 11L5350 2 v v HCF Clamp
–19 A2 90H3473 1 v HCF Key and Lock (with 41-4 and 41-5)
–4 A3, A4 NP 2 v v Key
–5 B3 NP 2 v v Lock
Appendix H. 2000-Sheet Input Drawer Option 777
Assembly 42: 2000-Sheet Input Drawer II
2321
22
24
2920
10
7
13
19
18 1211
98
hc2m022F
1 (with 2-25,29-31,33-36) 26 (with 2,4,5,33)
32 (with 30,31)
35
27 (with 7,8,24,35,E-RINGx1,KL-CLIPx1)
17
14
15
16
36
28 (with 14-17,36)
30
3131
4
44
4
5
2
6
34
34
33
25
1 2 3 4
1 2 3 4
A
B
C
A
B
C
Appendix H. 2000-Sheet Input Drawer Option 778
Table 99. Assembly 42: 2000-Sheet Input Drawer II
Asm–Index Grid
PartNumber Units Description
42– 90H0720 High-capacity feeder II
–1 A2 NP 1 v High-capacity feeder unit (with 42-2∼42-25, 42-29∼42-31, and 42-33∼42-36)
–2 A4 1 v v Rear cover (in kit P/N 90H3478) (see page 580)
–4 A3, A4 4 v v Spring (in kit P/N 90H3478) (see page 580)
–5 A3 1 v v Paper chute (in kit P/N 90H3478) (see page 580)
–6 B4 NP 1 v v Feeder frame assembly
–7 B3 1 v v Transport roll (in kit P/N 90H3479) (see page 580)
–8 C3 1 v v Right-hand lock (in kit P/N 90H3479) (see page 580)
–9 C2 90H3481 1 v v Right-hand cover open switch
–10 B2 90H3482 1 v Sensor
–11 C2 90H3483 1 v v Upper limit sensor
–12 C1 90H3484 1 v v No paper sensor
–13 C1 NP 1 v v Frame
–14 C2 1 v v Feed roller (in kit P/N 90H3480) (see page 580)
–15 C2 1 v v Feed roller bracket (in kit P/N 90H3480) (see page 580)
–16 C2 1 v v Right-hand feed roller bracket (in Kit P/N 90H3480) (see page 580)
–17 C1 1 v v Left-hand feed roller bracket (in Kit P/N 90H3480) (see page 580)
–18 C1 90H3485 1 v v Tray set sensor 1
–19 C1 90H3486 1 v v Tray set sensor 2
–20 B1 90H3487 1 v v Left-hand cover open switch
Appendix H. 2000-Sheet Input Drawer Option 779
Table 99. Assembly 42: 2000-Sheet Input Drawer II (continued)
Asm–Index Grid
PartNumber Units Description
42– 90H0720 High-capacity feeder II
–21 A1 90H3488 1 v v Transport motor
–22 B1 90H3489 1 v v Belt
–23 A1 06L9750 1 v v Gear
–24 B2 1 v v Left-hand lock (in kit P/N 90H3479) (see page 580)
–25 A2 06L9996 1 v v Low voltage power supply
–29 B1 11L5351 1 v v HCF Flat Harness
–30 A3 1 v v Connector harness (in kit P/N (see page 580) 11L5352)
–31 A3 NP 1 v v Screw
–33 A4 1 v v Strap (in kit P/N 90H3478) (see page 580)
–34 A4, B4 11L5353 2 v v HCF Clamp
–35 B1 1 v v Spacer (in kit P/N 90H3479) (see page 580)
–36 C2 1 v v Spring (in kit P/N 90H3480) (see page 580)
–26 A3 90H3478 1 Kit, rear cover (with 42-2∼42-5, and 42-33)
–27 B2 90H3479 1 Kit, transport roll (with 42-7, 42-8, 42-24, 42-35, E-ring, and KL-Clip)
–28 C2 90H3480 Kit, feed roller (with 42-14∼42-17, and 42-36) (includes the feed motor)
–32 A2 11L5352 1 HCF Connector Kit (with 42-30 and 42-31)
Appendix H. 2000-Sheet Input Drawer Option 780
GlossaryThe following terms are defined as they are used in this publication. If you do not find the term you need, seethe IBM Dictionary of Computing, New York, McGraw-Hill, 1994, or the IBM Dictionary of Printing.
The following cross-references are used in this glossary:v Contrast with refers to a term that has an opposite meaning.v See refers to a preferred term with the same meaning.v See also refers to related terms.
AA4-size paper. Paper that is 210 by 297 mm (8.3 x 11.7 in.).
ac. Alternating current
asm. Assembly
attention notice. An attention warns of possible of damage to a program, device, system, or data. Attention notices are locatedthroughout this publication. Attention notices are not translated.
aux. Auxiliary
BB5-size ISO paper.. Paper that is 176 mm by 250 mm (6.93 in. by 9.84 in.). B5-size JIS paper. Paper that is 182 mm by 257mm (7.17 in. by 10.12 in.).
BCR. Bias charge roller.
BTR. Bias transfer roller.
© Copyright IBM Corp. 1998 781
Ccaution notice. A notice that calls attention to a condition that is potentially dangerous to people.
CCW. Counterclockwise
charge. The negative voltage that the HVPS applies to the surface of the drum.
CM. Charge metering.
continuity. A resistance reading of approximately zero (0) ohms.
CR. Signal name for the charge voltage.
CRU. Customer replaceable unit, such as the EP cartridge.
CW. Clockwise
Ddanger notice. A notice used to call attention to a condition that is potentially deadly or extremely dangerous.
DB. Signal name for the developer bias voltage.
dc. Direct current.
default. An adjustment or setting that is set at the time of equipment manufacture.
detack. Separating the toned sheet of paper from the surface of the drum after imaging.
develop. The process when toner adheres to the latent image on the drum.
developed image. The visible image on the drum after going through the development process.
DPI. Dots per inch. The number of dots per inch printed by a laser printer. Each dot is either on or off, printed or not printed.See also (PPI).
DRAM. Dynamic random-access memory.
Glossary 782
drum. The electrophotographic receptor.
DTS. Signal name for the deteck saw voltage.
duplex. Printing on both sides of a single sheet of paper.
EEP. Electrophotographic.
EP cartridge. The electrophotographic cartridge; sometimes referred to as the print cartridge, the toner cartridge, or as theCRU.
error code. A unique set of letters and numbers that the printer displays to indicate that a problem exists in a specific area ofthe printer.
ESD. Electrostatic discharge, which if discharged into the circuitry of an integrated circuit, can damage the circuit.
exposure. The action of the laser beam striking and discharging select areas of the electrically charged surface of the drum.
FFG. Frame ground.
FU. Face-up. This abbreviation is used in some display messages.
fuser. The printer subsystem that uses heat and pressure to permanently adhere, or fuse, a transferred toner image to a sheetof paper.
Gground. Electrical ground.
Glossary 783
Hharness. A bundle of wires that form a single unit and are generally terminated with connectors at both ends.
HCF. High capacity feeder, or 2000-Sheet Input Drawer
HCI. High capacity input
high. A signal voltage that is equal to or almost equal to the base voltage; such as +5 V dc or +24 V dc. See also low.
HVPS. High voltage power supply.
Iimage density. The relative darkness of the latent image on a sheet of paper.
image development. Toner turning the latent image into a visible image. See also develop.
image fusing. Using heat and pressure to permanently adhere a toned image to a sheet of paper.
image transfer. Moving the developed image from the surface of the drum to the surface of a sheet of paper.
interlock. Interlock switch. Used as a safety measure to remove voltage from circuits whenever a printer cover or the like isopened.
JJ. Jack. A female electrical connector. See also P and P/J.
KKB. Kilobyte. 1 024 bytes.
Kb. Kilobit. 1 024 bits.
Glossary 784
Llaser. Refers to the laser diode or to the laser beam.
laser diode. Generates the laser beam that is used in the laser unit.
laser beam path. The path that the laser beam takes, through lenses and mirrors, from the laser diode to the surface of thedrum.
latent image. The visible, electrical image remaining on the surface of the drum after exposure.
LCD. Liquid crystal diode.
LED. Light emitting diode.
LEF. Long edge feed.
legal-size paper. Paper that is 216 mm x 356 mm (8.5 in. x 14.0 in.). letter-size paper. Paper that is 216 mm x 279 mm (8.5 in.x 11.0 in.).
low. A signal voltage that is significantly lower than the base voltage. See also high.
LVPS. Low voltage power supply.
MMB. Megabyte. 1 024 000 bytes.
Mb. Megabit. 1 024 000 bits.
MBF. Multi-bypass filter.
MCU. Machine control unit.
Glossary 785
NNC. No connection.
NOP. No paper.
NVRAM. Non-volatile random access memory.
PP. Plug A Male electrical connector.See also J and P/J.
P/J. Plug/jack. A connected male (plug) and a female (jack). See also J and P.
pel. See pixel.
pixel (pel). (1) The smallest distinct element of a raster image or an image displayed on a monitor. (2) The elementarygraphical cell that constitutes an image. (3) An element of a raster pattern or a point where a toned area on a photoconductorcan appear. Pixels per inch (ppi). The number of pixels per linear inch. Unlike dots, which are bilevel entities, pixels can holdmultiple levels of information. See also dots per inch.
point. A unit of measurement for describing type sizes. There are 12 points to a pica; about 72 points to an inch.
PPI. Pixels per inch. See also dots per inch (DPI).
PPM. Pages per minute.
print surface. The side of a sheet of paper that receives the printed image.
RRTN. Return.
Glossary 786
SSEF. Short edge feed.
sensor. A device used to monitor a function or an operation, such as paper travel along the paper path.
SG. Signal ground.
signal name. A name given to a wire indicating the purpose of the wire and/or the voltage carried by that wire.
SIMM. Single inline memory module.
simplex. Generally means printing only on one side of a sheet of paper. See also duplex.
SOS. Start of scan.
Ttoggle. To switch between two states, such as on and off or up and down.
toner. The dry ink that is used to create the visible image. Toner is stored in the EP cartridge.
TR. Signal name for transfer current.
transfer. Moving the toner image (developed image) from the surface of the drum to the surface of a sheet of paper.
Glossary 787
IndexAasm. locations
duplex 362env. feeder 362printer 362
assembly locations 547
Bbooks, obtaining from web 603
Ccable
ESD (electrostatic discharge) 20cable, ESD (electrostatic discharge)
20CAUTION notice 7cleaners and lubricants 588clutch locations
env. feeder 364printer 364
code updates, obtaining from web 603commonly used
fasteners 588parts 587
completing your task 36components, electrical, location 364connector locations
printer 367
DDANGER notice 6defects, print quality 34detergent 588diagnostic quick path 28diagnostics
See getting started 25test prints, running
paper path 251disposal of materials 8documents, obtaining from web 603
Eelectrical system
safety 8error codes and messages 30
000–099 30, 31, 32ESD
procedures 20
Ffasteners, common 588fault isolation
See diagnostic quick path 28fixes, obtaining from web 603
Ggathering information 26getting started 25
grease 588ground wires, locating 13guides, obtaining from web 603
Hhome page, Printing Systems Company
603
Iinformation, gathering 26instructions, safety inspection 12intermittent problems or errors 133
Llaser safety 10locations
asms.duplex 362env. feed 362printer 362
clutchesenv. feeder 364printer 364
connectorsprinter 367
electrical components 364clutches, solenoids 364miscellaneous 390sensors 384
© Copyright IBM Corp. 1998 788
locations (continued)mechanical
duplex 391printer 390
mechanical components 390PCBs
duplex 380env. feeder 380printer 380
quick path 361sensors
duplex 384, 386env. feeder 384, 386printer 384, 386
solenoidsenv. feeder 364printer 364
switchesduplex 384, 386env. feeder 384, 386printer 384, 386
lubricants and cleaners 588
Mmanuals, obtaining from web 603marking actions as completed, safetyinspection 13
mat, ESD 20mechanical, locations 390mechanical locations
duplex 391env. feeder 391printer 390
messagesSee error codes and messages 29
miscellaneous, locations 390
NNetwork Interface Card 541NIC 541notices
electrostatic discharge (ESD) 20safety
CAUTION 7DANGER 6description 6
safety precautions 8disposal of materials 8electrical safety 8laser safety 10ozone safety 11toner safety 11
trademarks 22
Ooil 588ozone safety 11
Ppaper path 251
test print 251parts, common 587parts catalog
assembly locations 548how to use
description 547
parts catalog (continued)how to use (continued)
grid 546part number 546units 547
parts catalog, how to useasm./index 546
parts location 547PCB locations
duplex 380env. feeder 380printer 380
print, paper path test 251print quality
defects 34print quality problems 33printer
safety inspection 13printer safety inspection 13Printing Systems Company web page
603problems
intermittent 133random 133
program fixes, obtaining from web 603
Qquick path, locations 361
Rrandom problems or errors 133reference items, safety inspection 13routine tasks 35
Index 789
running test printspaper path 251
Ssafety inspection 12
instructions 12marking actions as completed 13printer 13printer safety inspection 13reference items 13
safety noticesCAUTION 7DANGER 6description 6
safety precautions 8disposal of materials 8electrical safety 8laser safety 10ozone safety 11toner safety 11
sensor locationsduplex 384, 386env. feeder 384, 386printer 384, 386
sensorslocations 384
SIMM 539soap 588solenoid locations
env. feeder 364printer 364
START of CallSee getting started 25
status messages 239switch locations
duplex 384, 386env. feeder 384, 386printer 384, 386
Ttest print, paper path 251test prints, running 251toner safety 11trademarks 22troubleshooting
See getting started 25
Uupdates (code), obtaining from web
603utilities, obtaining from web 603
Wweb page, Printing Systems Company
603wrist band, ESD 20
Index 790
IBMR
Printed in the United States of Americaon recycled paper containing 10%recovered post-consumer fiber.
G544-5514-01