Professional Documents
Culture Documents
Service Guide
Note Before using this information and the product it supports, be sure to read the general information in Notices on page 5.
Second Edition (August 1998) This edition applies to Release 2.0 of the IBM InfoPrint 20 Service Guide, G544-5514-01. The following paragraph does not apply to any country where such provisions are inconsistent with local law. INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION AS IS WITHOUT WARRANTY OF ANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or implied warranties in certain transactions; therefore, this statement may not apply to you. Order publications through your IBM representative, your IBM Printing Systems Company printing specialist, or the IBM branch office serving your locality. Publications are not stocked at the address given below. IBM Printing Systems Company home page: http://www.printers.ibm.com IBM and the IBM Printing Systems Company welcome your comments. Either fax your comments to 1-303-924-6873, e-mail them to PRINTPUB@US.IBM.COM, or mail them to: Department H7FE, Building 003G The IBM Printing Systems Company Information Development P.O. Box 1900 Boulder, CO 80301-9191, U.S.A. When you send information to IBM, you grant IBM a non-exclusive right to use or distribute the information in any way it believes appropriate without incurring any obligation to you. Copyright International Business Machines Corporation 1998. All rights reserved. Note to U.S. Government UsersDocumentation related to restricted rightsuse, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corporation. Copyright International Business Machines Corporation 1998. All rights reserved. Note to U.S. Government Users Documentation related to restricted rights Use, duplication or disclosure is subject to restrictions set forth in GSA ADP Schedule Contract with IBM Corp.
Appendix G. 500-Sheet Paper Tray Option on page 661 Appendix H. 2000-Sheet Input Drawer Option on page 703 Index on page 788
Notices
References in this publication to IBM products, programs or services do not imply that IBM intends to make these available in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service is not intended to state or imply that only IBMs product, program, or service may be used. Any functionally equivalent product, program, or service that does not infringe any of IBMs intellectual property rights may be used instead of the IBM product. Evaluation and verication of operation in conjunction with other products, except those expressly designated by IBM, is the users responsibility. Any performance data contained in this document was obtained in a controlled environment based on the use of specic data. The results that may be obtained in other operating environments may vary signicantly. Users of this document should verify the applicable data in their specic environment. Therefore, such data does not constitute a performance guarantee or warranty. IBM may have patents or pending patent applications covering subject matter in this document. The furnishing of this document does not give you any license to these patents. You can send license inquiries, in writing, to the IBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.
Safety Notices
There are three levels of safety notices: DANGER, CAUTION, and Attention.
Danger Notices
The word Danger indicates the presence of a hazard that has the potential of causing death or serious personal injury. Danger notices are numbered <1-10>, <1-11>, and so forth where they appear in the text of this manual. Use the notice number to locate the national language translation of that notice in the IBM InfoPrint 20: Safety Instructions. Example danger notice:
Notices 6
Caution Notices
The word Caution indicates the presence of a hazard that has the potential of causing moderate or minor personal injury. Caution notices are numbered <2-20>, <2-21>, and so forth where they appear in the text of this manual. Use the notice number to locate the national language translation of that notice in the IBM InfoPrint 20: Safety Instructions. Example caution notice:
Notices 7
Electrical Safety
This printer is inspected and listed by recognized national testing laboratories, such as Underwriters Laboratories, Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of a product by a national testing laboratory indicates that the product is designed and manufactured in accordance with national requirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in design and manufacture. Remember, however, that this product operates under conditions of high electrical potentials and heat generation, both of which are functionally necessary. Because the paper and toner used in the printer can burn, take normal precautions to prevent re. These precautions include common-sense measures, such as keeping potentially combustible materials (for example, curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limiting unattended
Notices 8
operation, and having trained personnel available and assigned to the printer.
Notices 9
Laser Safety
This printer complies with the performance standards set the by U.S. Food and Drug Administration for a Class 1 Laser Product. This means that the printer belongs to a class of laser products that does not produce hazardous laser radiation in a customer access area. This classication was accomplished by providing the necessary protective housing and scanning safeguards to ensure that laser radiation is inaccessible or within Class 1 limits. There are various tool-operated machine covers that should be moved, removed, or replaced only by trained service personnel. There are no operator controls or adjustments associated with the laser. No operator maintenance is required to keep the product in compliance as a Class 1 Laser Product. No adjustments that affect laser operation or power are accessible to the operator. See the IBM InfoPrint 20: Safety Instructions for national language translations regarding laser safety.
Notices 10
Ozone Safety
An innitesimal amount of ozone gas (O3) is generated during corona discharge from the transfer charge roller. The ozone gas is emitted only when the printer is operating. This printer meets the ozone emission reference value set by Underwriters Laboratory (UL) at the time it is shipped from the factory.
Toner Safety
Toner is a non-poisonous substance composer of minute, plastic components. If toner adheres to your skin or to your clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hot water, the toner will gel and become difficult to remove. As toner easily breaks down vinyl materials, avoid letting toner come into contact with vinyl.
Notices 11
Safety Inspection
See Danger Notices on page 6 and Caution Notices on page 7 for an explanation of these notices.
Instructions
Perform a safety inspection before performing any of the following tasks: v Accepting a machine for a service agreement v Providing per-call service v Relocating a machine v Reviewing changes or attachments on any IBM machine that is leased, on service agreement, or on per-call service Correct unsafe conditions before you continue. Possible safety hazards are: v ElectricalAn electrically charged frame, or exposed wires or connections, can cause serious electrical shock. v MechanicalA missing safety cover or shield is hazardous. Moving parts, such as gears, shaft, and pulleys are hazardous. v ChemicalUse only approved cleaning agents. Do not use other solvents or chemicals.
Notices 12
Reference Items
You need the following items: v A copy of the machine EC history v Electrical Safety for IBM Customer Engineers, S229-8124
8. Inspect the covers and access panels for damage. 9. Ensure that all warning labels are in place. 10. If you are placing this printer on a service contract with IBM, check for changes not made by IBM. If you nd changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBM branch office. Complete the form and return it to the branch office. 11. Ensure that all ground connectors are correctly connected and tight (see Figure 1 on page 15 and Figure 2 on page 16.) 12. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. The reading must not exceed 0.1 ohm. 13. Inspect all cables, connections, and plugs for worn or damaged wiring.
Notices 13
14. Check for signs of contamination, corrosion, smoke, or burning. If there are signs of smoke or burning, check the Maintenance Agreement Qualication (MAQ) form for the correct repair procedure. 15. Replace all covers and access panels. The printer system diagram and ground locations are shown below. For a detailed description of the signals, see Chapter 4. Circuit Diagrams on page 307.
Notices 14
(SCANNER ASSEMBLY)
SCANNER MOTOR FG
SG
(HVPS)
(FUSER ASSEMBLY) TEMPERATURE SENSOR ASSEMBLY (HEATER ROD) THERMOSTAT THERMAL FUSE
HEATER ASSEMBLY
SG
(INTERLOCK SWITCH)
ACN
ACL
FAN ALARM
5VDC SUPPLY
24VDC
(FAN)
AC L FUSE
24VDC SUPPLY
FAN CONTROL
FAN ON
AC N POWER SWITCH FG SG
RTN
hc2m004F
FG
Notices 15
Lug
hc2m131F
Notices 16
Power-Receptacle Safety-Check
See Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and procedures before performing any of the following tasks. (Electrical Safety for IBM Customer Engineers, S229-8124 may not be applicable for other countries): v Checking ac voltage at the power receptacle v Checking ac impedance to ground at the power receptacle Perform the power receptacle safety check as described in Electrical Safety for IBM Customer Engineers, S229-8124. Use only the applicable high-voltage probes. See the applicable table below for the permitted ac voltage range and record the voltage measured: v See Table 1 on page 18, Nominal AC Line Voltages at Power Receptacle (110 V ac120 V ac) v See Table 2 on page 18, Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac) v See Table 3 on page 19, Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac, 3 Phase Wye Connected)
Notices 17
Notices 18
Table 3. Nominal AC Line Voltages at Power Receptacle (220 V ac240 V ac, 3 Phase Wye Connected)
Nominal Line Voltages 3-Phase Wye Connected 200, 208, 220, 230, and 240 V ac Phase to Neutral 50 Hz 180259 V ac 60 Hz 180254 V ac 50 Hz 180259 V ac 60 Hz 180254 V ac <1.0 V ac Recorded Line Voltages V ac V ac V ac V ac V ac
Notices 19
Notices 20
8. Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working with connectors. 9. Be careful when working with ESD-sensitive parts when the humidity is low. Low humidity increases static electricity.
Notices 21
Trademarks
The following terms are trademarks of the IBM Corporation in the United States or other countries or both: AIX AIX/6000 IBM InfoPrint OS/2 Personal System/2 PS/2 RISC System/6000 WIN-OS/2 The following terms are trademarks or registered trademarks of other companies:
Acrobat Adobe Adobe logo Apple Apple logo Ethernet Macintosh Microsoft Mylar Novell PostScript UNIX Windows Adobe Systems, Inc. Adobe Systems, Inc. Adobe Systems, Inc. Apple Computer, Inc. Apple Computer, Inc. Xerox Corporation Apple Computer, Inc. Microsoft Corp. E. I. du Pont de Nemours & Co., Inc. Novell Inc. Adobe Systems, Inc. AT&T Corporation Microsoft Corp.
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Related Publications
To obtain additional copies of this book or of any related publication, contact your IBM service representative, your authorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755 or 1-919-713-4055.
Document These service documents must be ordered separately: v IBM InfoPrint 20: Service CD-ROM. The Service CD-ROM includes the service guide for the IBM InfoPrint 20, as well as the customer documents that ship with the printer. These documents are viewable using Adobe Acrobat Reader, which is included on the CD-ROM. v IBM InfoPrint 20: Service Guide (Hardcopy) These books are included with the printer: v IBM InfoPrint 20: Users Guide v IBM InfoPrint 20: Quick Setup Poster v IBM InfoPrint 20: Safety and Warranty Information These books are included with the optional network cards: v IBM Network Printers: Ethernet and Token Ring Conguration Guide v IBM Network Printers: Twinax and Coax Conguration Guide These technical references must be ordered separately: v IBM Network Printers: PCL5e and PostScript Level 2 Technical Reference v IBM Network Printers: IPDS and SCS Technical Reference S544-5344 S544-5312 G544-5240 G544-5241 S544-5516 S544-5515 G544-5524 GK2T-9265 Number
G544-5514
Introduction
Chapter 1. Getting Started quickly guides you through problem isolation. Dening the Problem on page 26 reviews the information necessary to accurately dene any printer problem. With your printer problem dened, Diagnostic Quick Path on page 28 directs you to the correct diagnostic or repair procedure. See Miscellaneous, Routine Tasks on page 35 for miscellaneous or routine tasks. Completing Service on page 36 is a quality-of-service assurance checklist.
25
The printer prints, but has poor print quality. Using this information, go to Diagnostic Quick Path on page 28.
Completing Service
Note: If you replaced a part that did not correct the problem, reinstall the original part. If the printer has not been xed using the procedures that you were directed to perform, return to Diagnostic Quick Path on page 28. Ensure that you have correctly interpreted the available information, and then dene the problem again. If a solution is not found, call your next level of support (see Appendix D. Technical Support on page 602). Use the following as a guide to ensure high quality printer operation: 1. Ensure the following: a. All internal cables and connectors are correctly connected. b. All covers, doors, panels, and trays are in place. c. Any workstation or network cable is connected. d. All power cords are connected. 2. Switch on printer power and ensure the following: a. IBM INFOPRINT 20 displays. b. WARMING UP displays. c. READY displays within approximately 2-minutes or the printer begins printing if a job is in the print queue. 3. Run test prints from the operator panel to ensure high quality output. Show these to the operator. 4. Have the operator run a print job. 5. Clean the work area. 6. Clean the printer covers with a dry cleaning cloth; if necessary, use water and a mild detergent (non-ammonia). 7. Return control of the printer to the operator.
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. 41 . 43 . 44 . 45 . 46 . 49 . 50 . 52 . 54 . 55 . 58 . 64 . 64 . 64 . 65 . 68 . 68 . 69 . 73 . 83 . 84 . 89 . 94 . 94 . 98 .101 .101 37
32 PRINT OVERRUN . . . . . . . . . . . 40 MEMORY OPTION ERROR . . . . . . 41 NETWORK OPTION ERROR . . . . . 42 NETWORK OPTION ERROR . . . . . 43 PS OPTION ERROR . . . . . . . . . . 44 IPDS OPTION ERROR. . . . . . . . . 45 OPTION ERROR . . . . . . . . . . . . 46 NETWORK OPTION ERROR . . . . . 50 ERROR CALL FOR SERVICE . . . . . 51 ERROR CALL FOR SERVICE . . . . . 52 ERROR CALL FOR SERVICE . . . . . 53 ERROR CALL FOR SERVICE . . . . . 54 ERROR CALL FOR SERVICE . . . . . 55 ERROR CALL FOR SERVICE . . . . . 56 ERROR CALL FOR SERVICE . . . . . 61 ERROR CALL FOR SERVICE . . . . . 62 ERROR CALL FOR SERVICE . . . . . 63 ERROR CALL FOR SERVICE . . . . . 71 DISK ERROR . . . . . . . . . . . . . 72 DISK ERROR . . . . . . . . . . . . . 73 DISK ERROR . . . . . . . . . . . . . 80 ADD MEMORY FOR IPDS . . . . . . . 80 ADD MEMORY FOR PAGES, ESC/P . 81 INSUFFICIENT MEMORY FOR IPDS . 81 INSUFFICIENT MEMORY FOR PAGES 82 HOST TIMEOUT . . . . . . . . . . . . 83 CX SEND STATE. . . . . . . . . . . . 84 NO FONT SIMM FOR PAGES, ESC/P . Printer Problems without Error Codes . . . . Fuse or Power Problem . . . . . . . . . .
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.101 .101 .102 .102 .103 .103 .104 .104 .105 .108 .109 .114 .119 .120 .122 .123 .123 .124 .124 .124 .125 .125 .125 .125 .125 .126 .126 .126 .127 .127
Intermittent or Random Problems . . . . . . . . Operator Panel, Controller, and Power Problems Toner Low and No Error Code 02 Displayed . . Other Diagnostics . . . . . . . . . . . . . . . . . 24V Power Supply to MCU . . . . . . . . . . . Electrical Noise . . . . . . . . . . . . . . . . . Ethernet / Token-Ring NIC Printing Problems . . Feed Solenoid . . . . . . . . . . . . . . . . . . HVPS . . . . . . . . . . . . . . . . . . . . . . LVPS. . . . . . . . . . . . . . . . . . . . . . . Paper Size Switch - 500-Sheet Paper Trays. . . Pick Up Solenoid (Auxiliary Tray) . . . . . . . . Registration Sensor . . . . . . . . . . . . . . . Toner Sensor . . . . . . . . . . . . . . . . . . Twinax / Coax NIC Printing Problems . . . . . . Print Quality . . . . . . . . . . . . . . . . . . . . Background . . . . . . . . . . . . . . . . . . . Black Prints . . . . . . . . . . . . . . . . . . . Blank Prints . . . . . . . . . . . . . . . . . . . Black Horizontal Stripes . . . . . . . . . . . . . Damaged Print. . . . . . . . . . . . . . . . . . Fusing, Not Fused or Partially Fused Image. . . Light (Undertoned) Prints . . . . . . . . . . . . Residual Image . . . . . . . . . . . . . . . . . Skewed Image . . . . . . . . . . . . . . . . . . Spots . . . . . . . . . . . . . . . . . . . . . . Streaks, Horizontal. . . . . . . . . . . . . . . . Streaks, Vertical . . . . . . . . . . . . . . . . . Unusual Patterns . . . . . . . . . . . . . . . . Voids. . . . . . . . . . . . . . . . . . . . . . .
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.133 .135 .142 .144 .144 .146 .150 .155 .159 .163 .165 .170 .172 .176 .179 .184 .184 .188 .191 .195 .196 .200 .203 .208 .212 .216 .219 .223 .227 .229
General Information
The Diagnostic Quick Path should have directed you to this section to analyze your printer problem. 1. Diagnostics assume there are no code problems in the printer controller. If you are unable to x a problem using the diagnostics, we recommend that you replace the printer controller and obtain the latest level code. 2. Diagnostics frequently use new or known good components as diagnostic tools. We recommend you carry a spare Toner Cartridge (EP Cartridge), MCU PWB, Printer Controller PWB, and Power Supply PWB. 3. Unless indicated otherwise, the instruction switch ON main power means for you to SWITCH ON printer power and let the printer proceed through power-on diagnostics and warm-up until it is on-line and ready to print. 4. Unless indicated otherwise, you should inspect and conrm the status of those components listed under the title of SUSPECT COMPONENTS at the rst part of each diagnostic. The inspection items are: v Installed properly? v Not damaged or deformed? v Not contaminated with foreign material? 5. If you cannot isolate the problem using the diagnostics, replace each component listed under the title of SUSPECT COMPONENTS at the rst part of each diagnostic, one at a time, until the problem is xed. 6. Conventions used to represent connectors, v P/J XX means that the Plug and its corresponding Jack are connected. v PXX means that the Plug is disconnected. (Unless this plug is soldered to a PWB). v JXX means that the Jack is disconnected. (Unless this jack is soldered to PWB). 7. When you are instructed to take a voltage reading between P/J A-B and P/J X-Y, place the red probe (+) of your meter on pin B of P/J A, and place the black probe (-) of your meter on pin Y of P/J X. 8. When you are instructed to take a voltage reading between P/J X and P/J Y (without specied pin numbers), check all voltage carrying pins. See the Wiring Diagrams for signals and pin numbers.
Chapter 2. Diagnosing Problems 41
9. Plug numbers are indicated on the circuit board. In there are 8 pins in a plug, you can nd a 1 (or A) at one end and an 8 or (H) at the other end. The other pins, such as 6, are found by counting from one end. 10. When you are instructed to take a voltage reading, the black probe (-) is generally connected to a pin that is either RTN (Return) or FG (Frame Ground) in place of any SG pin or test point. 11. Unless an diagnostic instructs you otherwise, before measuring voltages make sure the printer is switched ON, the Print Cartridge and the Paper Cassette are installed, and the Exit Cover is closed (Interlock Switch is actuated). 12. All voltage values given in the diagnostics are approximate. Measured voltages may vary more than 25% from the values stated in the diagnostics. The main purpose of most voltage readings taken in the diagnostics is to determine whether or not a component is receiving the correct high voltage value from the power supply and if gating (a voltage drop) occurs during component actuation. Gating signals may be nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossible to read on a multimeter. 13. Diagnostics may instruct you to remove or replace a component. See Chapter 6. Removal Procedures, Adjustments on page 394 for information on how to remove and reinstall a component. 14. When a diagnostic instructs you to replace a component and that component is part of a larger assembly, you should replace the entire assembly.
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.
Diagnostics
Diagnostic Quick Path on page 28 is the entry point for all problems. If at any point the diagnostic to which you have been directed does not solve the problem, return to the Diagnostic Quick Path. Diagnostics are listed as follows: 1. Error Codes with Messages on page 45 Error codes with messages are described here. 2. Printer Problems without Error Codes on page 127 You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post an error code. 3. Other Diagnostics on page 144 These are secondary diagnostics pointed to by other diagnostics. 4. Print Quality on page 184 Each of these diagnostics has an illustration of the print quality symptom discussed in the diagnostic.
02 TONER LOW
Meaning: The EP Cartridge is nearing end-of-life and should be replaced. This error can also occur if the EP Cartridge is misaligned, caused by the side guides or BTR assembly. Action: Press the Continue key to continue printing (the TONER LOW message remains on the display). Ensure that a new EP cartridge is available. When the print quality becomes unacceptable, install a new EP cartridge. The TONER LOW item on the Paper Menu lets you specify whether or not you want the printer to stop printing when it detects a TONER LOW condition. If toner is low and error code 02 does not display, go to Toner Low and No Error Code 02 Displayed on page 142. If this action does not x the problem, go to Table 10.
Table 10. 02 TONER LOW
Step Actions and Questions SUSPECT COMPONENTS v EP Cartridge (Asm-Index: 11-40, page 572) v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v Toner Relay Harness (Asm-Index: 12-18, page 575) v MSI Bracket Assembly (Asm-Index: 5-7, page 557) v MCU PWB (Asm-Index: 12-8, page 575) EP CARTRIDGE 1. Install a new EP Cartridge. Does the Error Code 02 TONER LOW still appear? Go to step 2 Verify the x. Also verify that the problem job prints. Yes No
2.
FUNCTION OF TONER SENSOR Replace the a. Use D21 SENSOR TEST on page 261 to check the function of the Toner MCU, or there is an EP cartridge Sensor Assembly. alignment Note: The Pop Up Unit must be closed in the next step. problem. b. Depress the switch with a non-magnetized piece of steel. Does the Toner Sensor function correctly?
3.
TONER SENSOR CONNECTION Is the Toner Sensor connection (P/J221) OK? TONER SENSOR ASSEMBLY (Asm-Index: 5-13, page 557)
Go to step 4
Repair as needed
4.
Install a new Toner Sensor Assembly (See page 462). Is the problem xed? TONER RELAY HARNESS
Verify the x. Also Go to step 5 verify that the problem job prints. Go to step 6 Repair as needed
5.
Inspect the Toner Relay Harness (P/J22 at the MCU; P/J222 at the Toner Sensor Harness). Is the harness OK? MSI BRACKET ASSEMBLY (Asm-Index: 5-7, page 557)
6.
Replace the MSI Bracket Assembly (See page 457). Is the problem xed?
Verify the x. Also Go to the last verify that the step of this problem job diagnostic. prints.
7.
Verify the x. Also Go to step 5 verify that the problem job prints. Replace the MCU Repair as needed PWB (See page 526 or 529)
6.
4.
5.
3.
6.
End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
1.
2.
Go to step 5
5.
6.
10.
12.
16 TRAY n MISSING
Meaning: Paper Cassette (Tray 1), Tray 2 or Tray 3 are not in place. Action: Open and close the tray. If you have not installed the tray, do so at this time. If this action does not x the problem, go to Table 15.
Table 15. 16 TRAY n MISSING
Step Actions and Questions SUSPECT COMPONENTS v Tray 1 Problems: Feeder PWB (Asm-Index: 3-1, page 553) Cassette Guide L (Asm-Index: 3-7, page 553) Paper Cassette (Asm: 2, page 550) v Tray 2 Problems: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) v Tray Harness (Asm-Index: 12-17, page 575) v General: MCU PWB (Asm-Index: 12-8, page 575) Does the Error Code specify Tray 2 or Tray 3? 1. Go to Appendix G. 500-Sheet Paper Tray Option on page 661 Go to step 2 Yes No
Replace the MCU Go to Paper Size PWB (See page Switch 526 or 529) 500-Sheet Paper b. Use D21 SENSOR TEST on page 261 to check the function of the Paper Trays on Size Switch. page 165 c. Reach inside the paper feeder and press and release each Size Actuator (Asm-Index: 3-8, page 553), one Actuator at a time, pressing ENTER between each Actuator tested. Do the Size Switches function correctly? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
6.
20 PAPER JAM
Meaning: There is a paper jam at the Exit Sensor (Exit Photo Sensor). Action: Remove jammed paper from the paper path. Open and close the top cover. If this action does not x the problem, go to Table 16.
Table 16. 20 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor v Duplex Unit (Asm: 30, page 652) v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v Exit Cover (Asm-Index: 1-12, page 548) 1. PAPER CONDITIONS Is the paper wrinkled, damaged, or damp? 2. Switch ON main power. Is 20 PAPER JAM displayed when you Switch ON power? PAPER AT EXIT ACTUATOR (Asm-Index: 8-24, page 564) 3. a. Open the Fuser Cover. b. Open the Fuser Access Cover. Is there paper at the Exit Actuator inside the Fuser? Remove the Go to step 10 paper. Go to step 4. Replace with fresh, dry paper Go to step 3 Go to step 2 Yes No
Go to step 5
Verify the x. Also Go to step 5 verify that the problem job prints. Ensure that the Go to step 6 Duplex Unit is installed correctly and plugged into the duplex connection. If it is, go to Appendix E. Duplex Unit Option on page 604. Replace the Fuser Assembly (See page 487)
DUPLEX UNIT (Asm-Index: 30-1, page 652) Does the problem appear using the Duplex Unit? 5.
CAUTION: Go to step 7 <2-35> Remove all watches, rings, jewelry, and other articles (such as a necktie) that may catch on printer parts before working in this area. ROTATION OF EXIT ROLL ASSEMBLY (Asm-Index: 9-31, page 567) 6. a. Switch ON main power. b. Inspect the rotation of the Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly (Asm-Index: 8-6, page 564) during the warm up period. Does the Exit Roll Assembly and the Pinch Roll of the Fuser Top Cover Assembly rotate smoothly?
9.
Verify the x. Also Go to step 12 verify that the problem job prints.
13.
21 PAPER JAM
Meaning: Misfeed jam. There is a paper jam between the paper inputs (Tray 1, 2, 3, AUX Tray) and the Registration Sensor. Action: Remove jammed paper from the paper path. Make sure paper is loaded correctly. Open and close the top cover. Note: If the 21 PAPER JAM error occurs only when paper re-enters the printer from the duplex option, go to 22 PAPER JAM (or 21 PAPER JAM from Duplex) on page 608. SUSPECT COMPONENTS v Jams only from Auxiliary Tray: Transport Chute Assembly (Asm-Index: 6-2, page 559) MSI No Paper Sensor (Asm-Index: 5-9, page 557) MSI No Paper Actuator (Asm-Index: 5-10, page 557) Pick Up Solenoid (Asm-Index: 6-17, page 559) Pick Up Roll (Asm-Index: 6-9, page 559) Retard Pad Assembly (Asm-Index: 6-18, page 559) Front Bottom Tray (Asm-Index: 5-5, page 557) v Jams only from Tray 1: Cassette No Paper Sensor (Asm-Index: 3-11, page 553) Cassette No Paper Actuator (Asm-Index: 3-16, page 553) Feed Solenoid (Asm-Index: 4-8, page 555) Feed Roll (Asm-Index: 4-1, page 555) Feeder Harness (Asm-Index: 3-12, page 553). Use P/N 90H0775.
Chapter 2. Diagnosing Problems 73
v Jams from Tray 1 and possibly Tray 2 or 3: Electromagnetic Clutch, Turn Roll (Asm-Index: 4-9, page 555) Turn Roll Assembly (Asm-Index: 4-10, page 555) Rear Roll Assembly (Asm-Index: 4-11, page 555) Feeder PWB (Asm-Index: 3-1, page 553) Turn Chute Assembly (Asm-Index: 3-5, page 553) Turn In Chute (Asm-Index: 3-4, page 553) Paper Cassette (Asm: 2, page 550) Tray Harness (Asm-Index: 12-17, page 575) v Jams from any Tray: Registration Sensor (Asm-Index: 7-6, page 562) Registration Actuator (Asm-Index: 7-7, page 562) High Harness Assembly (Asm-Index: 6-5, page 559) v 500-Sheet Paper Tray Option Problems: 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page 697) v 2000-Sheet Input Drawer Problems: Treat as a 26 PAPER JAM on page 94 v General: MCU PWB (Asm-Index: 12-8, page 575) Main Gear Assembly (Asm-Index: 10-10, page 570) Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)
1.
3.
DUPLEX UNIT (Asm: 12, page 575) If a duplex option is not installed, go to step 7. 6. If a duplex option is installed, set PAPER MENU/DUPLEX=ON. Print using TEST MENU/CONTINUOUS TEST. Is duplex printing OK? PAPER OUT SENSING 7. From each source, remove all paper. Verify that printing a CONFIG PAGE from that source causes an 11 LOAD <size> IN <source> error. Is the paper out sensing for each source OK? Use the following chart to determine which step to go to (ignore references to options not installed). Aux Tray 1 Tray 2 Tray 3 Go to step: 8. OK OK bad bad OK OK OK OK bad bad bad OK OK bad bad bad bad OK bad bad 10 10 12 16 9
Paper out sensing problem. (For 500-sheet option, replace the 500-sheet option)
TRAY 1 PRINTING IS BAD 9. Observe the position of the paper from Tray 1 after the error occurs. Did the paper start to leave the cassette?
11.
TRAY SPRINGS v Remove the tray (cassette) from the option. Remove the paper. v Press the bottom plate down and ensure that it stays down. v Insert the tray in the option and ensure that the plate springs up. v Inspect the tray for other damage. v If another tray is available, use it for analysis. Is the tray OK? FRONT BOTTOM TRAY (Asm-Index: 5-5, page 557) You are starting analysis for jams only from the AUX Tray.
Go to step 14
Go to step 13
12.
a. Load paper in the Auxiliary Tray. Set PAPER MENU/SOURCE=AUX and verify PAPER MENU/AUXSIZE. Run a CONFIG PAGE. b. Inspect the Front Bottom Tray through Front Tray Opening. Is the Front Bottom Tray raised during printing?
13.
17.
20.
CAUTION: Mechanical <2-35> Remove all watches, rings, jewelry, and other articles problem in paper (such as a necktie) that may catch on printer parts before transport working in this area. TURN ROLL ASSEMBLY (Asm-Index: 4-10, page 555) and REAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555) 21. You are starting analysis for a Tray 1 turn roll problem. a. Install the Paper Cassette without the Cassette Cover. b. Run a CONFIG PAGE. c. While the paper is transported, inspect the rolls by opening the Turn Chute Assembly (Asm-Index: 3-5, page 553) at the rear of the printer. Do the rolls turn? ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555) Go to the last step of this Run D41 (see D41 CLUTCH TR (Turn Roll Clutch) on page 269). You should diagnostic. hear a clicking sound when the clutch activates. Note: If you have a 500-Sheet Tray 2, you will hear that clutch activate also. Put your nger on the Turn Roll Shaft near the clutch while activating D41 to determine if the clutch is activating. Does the Electromagnetic Clutch function correctly? ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555) 23. Replace the Electromagnetic Clutch (See page 449). Is the problem xed?
Go to step 23
22.
Verify the x. Also Replace the verify that the Feeder PWB (See problem job page 420) prints.
24.
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.
23 PAPER JAM
Meaning: There is a paper jam between the Registration Sensor and the Exit Sensor. Can also be caused if the paper did not reach the Exit Sensor from the Registration Sensor in the required time. Action: Clear the jam.
Table 18. 23 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor v Registration Clutch Assembly (Asm-Index: 10-9, page 570) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v BTR Assembly (Asm-Index: 6-1, page 559) v EP Cartridge (Asm-Index: 11-40, page 572) v Main Gear Assembly (Asm-Index: 10-10, page 570) v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570) v High Harness Assembly (Asm-Index: 6-5, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) 1. PAPER CONDITIONS Is the paper loaded in the paper tray wrinkled or damaged? Replace with fresh, dry paper Go to step 2 Yes No
Remove any Go to step 3 foreign material Note: Turn the registration roll by hand to remove hard to reach paper. The paper does not reach the exit actuator. Go to step 4.
3.
PAPER POSITION The exit sensing may be bad. Go a. If the Duplex Option is installed, remove it. Note: If paper jams do not occur with the Duplex Option removed, replace to step 11. the Duplex Option. b. Print TEST MENU/CONFIG PAGE until a 23 PAPER JAM occurs. c. Open the Fuser Cover Assembly. d. Open the Fuser Rear Cover (Asm-Index: 8-10, page 564). e. Inspect the position of paper when the error code 23 PAPER JAM is displayed. Did the paper reach or pass the Exit Actuator (Asm-Index: 8-24, page 564)?
4.
Fuser or main gear problem. Replace the EP Cartridge. If that does not x the problem, go to step 6.
Go to step 5
TRANSPORT ASSEMBLY (Asm-Index: 7-1, page 562) 5. Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) and the Rubber Registration Roll (Asm-Index: 7-11, page 562). Do the Metal Registration Roll and the Rubber Registration Roll rotate smoothly?
GEAR RELEASE MECHANISM OF MAIN GEAR ASSEMBLY (Asm-Index: 10-10, page 570) 8. a. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). b. Open and close the Pop Up Unit. Does the Gear Release Mechanism sink down when you open the Pop Up Unit, and rise up when you close the Pop Up Unit? ROTATION OF BTR ROLL AND EP CARTRIDGE DRUM Inspect the position of front edge of the paper. 9. Did the front edge of the paper pass between the BTR and the Drum?
Go to step 9
Go to step 10
Replace the BTR Assembly (See page 466), EP Cartridge, or the Transport Chute Assembly (See page 468)
12.
14.
24 PAPER JAM
Meaning: There is a paper jam between the Paper Cassette / Auxiliary Tray and the Registration Sensor. This often occurs when another paper jam has not been completely cleared. It can also occur if the paper arrives at the sensor early due to a premature paper pick. Note: If you were running a pick/feed diagnostic, D50 SOL TRAY A (Auxiliary Tray Feed Solenoid), D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid), D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid), or D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid), the 24 PAPER JAM may have occurred because a solenoid was pre-picked. Action: Remove jammed paper from the paper path. Open and close the top cover. If this action does not x the problem, go to Table 19 on page 90.
3.
6.
Determine which paper sources have the premature paper pick. 8. Is the problem only with the Auxiliary tray? Does the problem appear when using Tray 2 or 3?
9.
Go to Go to step 10 Appendix G. 500-Sheet Paper Tray Option on page 661 or Appendix H. 2000-Sheet Input Drawer Option on page 703
10.
There is a premature feed problem with Tray 1. Go to Feed Solenoid on page 155.
11.
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.
1.
2.
Go to step 4
There may be a problem causing Check the PAPER MENU/AUXSIZE setting. must match the paper size and slow paper orientation (LEF=Long Edge Feed, SEF=Short Edge Feed) of the paper in the feeding from the Auxiliary tray. Auxiliary tray. Is the setting OK? 2000-SHEET INPUT Go to Appendix H. 2000-Sheet Input Drawer Option on page 703 Go to step 6
4.
Does the problem appear when printing from the 2000-Sheet Paper Tray Option? PAPER LOADING
There is a problem with the Envelope option or an intermittent problem. Adjust the paper guides
5.
Check each paper tray and the paper guide adjustments. Does each tray have the size guides adjusted to match the loaded paper? TRAY SIZE SENSING a. Print TEST MENU/CONFIG PAGE. b. If an error occurs, press CONTINUE. c. On the CONFIG PAGE, under Auto Sensed Paper, compare the sizes listed to the paper sizes in the trays. Do the sizes match for all trays? Go to step 7
6.
7.
Paper loading and size sensing seem OK. If the error no longer occurs, it was probably caused by a multiple sheet feed. If the error still occurs, there may be a mechanical problem causing slow paper feeding.
8.
29 OUTPUT FULL
Meaning: The output bin is full. Without a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index: 8-8, page 564) in the Fuser Assembly. When a duplex option is installed, the printer monitors the Duplex Stack Actuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator. When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed on the operator panel. The printer continues to print a few more pages to clear the paper path before it stops. The 29 OUTPUT FULL message remains until the signals indicate that the paper stack has been removed. Notes: 1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printer stops after the paper path clears. 2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the user can remove the duplex unit and continue to print simplex jobs. Action: Remove the output from the bin. If this action does not x the problem, go to Table 21.
Table 21. 29 OUTPUT FULL
Step Actions and Questions SUSPECT COMPONENTS v Fuser Assembly (Asm-Index: 8-1, page 564), includes Full Stack Sensor v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v If the error only occurs with the Duplex Option, see 29 OUTPUT FULL, with Duplex Installed on page 610. Yes No
Go to step 3
The Full Stack Go to step 4 Sensor on the Fuser is disabled. Go to 29 OUTPUT FULL, with Duplex Installed on page 610. Go to step 5 Replace the Fuser Assembly (See page 487)
FULL STACK ACTUATOR and SENSOR (Asm-Index: 8-8 and 8-7, page 564) 4. a. Open the Fuser Cover Assembly. b. Push up and then release the Full Stack Actuator. c. Check the actuator and the sensor for correct operation. Are the actuator and the sensor OK? FULL STACK SENSOR (Asm-Index: 8-7, page 564) 5. a. Use D21 SENSOR TEST on page 261 to check the Full Stack Sensor. b. Press and release the Full Stack Actuator (Asm-Index: 8-8, page 564). Is the sensor OK?
Verify the x. Also Go to step 7 verify that the problem job prints.
7.
8.
30 MEMORY OVERFLOW
Meaning: Memory overow. The printer has received more data than it can t into its memory. This can happen when the printer receives too many soft fonts, macros, or complex graphics. Action: If the AUTOCONTINU item in the Cong Menu is set to ON, printing resumes in ten seconds. Otherwise, press the Continue key. Check the current page for errors.
32 PRINT OVERRUN
Meaning: A page is too complex to print at the current resolution. Action: Do one of the following: v If QUALITY is set to 1200, change it to something else (such as 600) and resubmit the job. Use your printer driver or the Cong Menu. The driver setting overrides the menu setting. v If you are feeding paper long-edge rst, change it to short-edge rst. v Have the customer add more memory.
43 PS OPTION ERROR
Meaning: The printer has detected a problem with the PostScript section of the Controller SIMM. Action: Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset as follows (this resets all values in printer NVRAM to factory defaults): 1. Print a conguration page Conguration Page on page 250. 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display. If the error recurs, replace the Controller SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).
45 OPTION ERROR
Meaning: The printer has detected a problem with a SIMM (probably the IPDS SIMM). Action: Reinstall all SIMMs. If the message recurs, replace the IPDS SIMM (See Controller PWB SIMM on page 539). If the error still recurs, replace the Controller PWB (See Controller PWB on page 537).
Replace the MCU Replace the High (See page 526 or Harness 529) Assembly
3.
7.
3.
Replace the LVPS Replace the MCU Assembly (See PWB (See page page 521), or the 526 or 529) LVPS Harness.
8.
9.
10.
1.
6.
12.
Replace the Main Replace the Main Motor (See page Motor (See page 489), or the MCU 489) PWB (See page 526 or 529)
13.
3.
1.
3.
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.
82 HOST TIMEOUT
Meaning: The coax network interface card has sent an Intervention Required message to the host. This error occurs when (a) the printer is OFFLINE for longer than the HLD TMEOUT setting in the Coax Setup Menu, or (b) the printer has been in an intervention required state (such as out of paper) for longer than the IRQ TMEOUT setting. Action: Solve the problem that caused the message (for example, press the Online key to put the printer online, or add paper). To disable this error message, set the HLD TMEOUT and IRQ TMEOUT values in the Coax Setup Menu to 0.
83 CX SEND STATE
Meaning: Your coax host has placed your printer in Send State and is waiting for the printer to return a PA signal. Action: Press the Continue key to clear the message. (You may need to press the key more than once.) Then do the following to send the PA signal. 1. Press the Online key to take the printer offline. 2. Press the Menu key until you see the Coax SCS Menu. 3. Press the Item key until you see PA1 or PA2 (whichever signal you want to send). 4. Press the Enter key to send the signal. 5. Press the Online key to resume printing.
1.
5.
7.
8.
If you suspect a controller problem, see Operator Panel, Controller, and Power Problems on page 135.
If you do not resolve the problem, return to Diagnostic Quick Path on page 28 and dene the problem again or call 18003586661 for technical support. If you exchange a part and the problem is not xed, reinstall the original part. Check the following: v v v v Disconnect and reseat connectors in the associated area. Check for loose, worn, or broken connectors and cables. Check the environment, such as ambient temperature and humidity. Check for RF noise such as a radio or TV transmitter.
1.
2.
4.
If the printer had only 1 DRAM SIMM, replace the SIMM (see Controller PWB The DRAM SIMM Go to step 5 SIMM on page 539). was bad Is the problem xed?
7.
Go to step 10
The MCU is Go to step 9 functioning correctly. Replace the Controller SIMM (See Controller PWB SIMM on page 539). If the problem still exists, replace the Controller PWB (See Controller PWB on page 537). The MCU is functioning correctly. Replace the Controller SIMM (See Controller PWB SIMM on page 539). If the problem still exists, replace the Controller PWB (See Controller PWB on page 537). Bad MCU or 5V power problem. Go to LVPS on page 163.
9.
Rerun Printing a Test Matrix Page Without the Controller, ensuring that the following are true: a. The paper path is clear. b. The EP cartridge is installed. c. Paper is loaded in Tray 1. d. The covers are closed. Do the test pages print OK?
Ensure that there are no paper jams, and that all covers are closed. Switch off Go to step 11 the printer power, then switch it back on. Do both the fan and motor activate? CONSOLE/OPERATOR PANEL Go to step 14
Go to step 12
11.
Wait one minute, watching the 4 lighted LEDs and display. Do the LEDs and display function correctly?
12.
Verify the connection at the console assembly and the controller. If the connections seem OK, replace the console assembly (See page 418). Is the problem xed? There is a problem with one of the following components: v Console Harness (Asm-Index: 13-6, page 578) v Controller Harness (Asm-Index: 13-8, page 578) v LVPS Assembly (Asm-Index: 12-4, page 575) When Online is pressed, the Online LED should turn off. The other keys control menus. Do the keys function correctly?
Verify the x. Also Go to step 13 verify that the problem job prints.
13.
14.
Verify the x. Also Go to step 12 verify that the problem job prints. Go to LVPS on page 163 Go to Fuse or Power Problem on page 127
15.
16.
3.
Other Diagnostics
These are secondary diagnostics branched to by other diagnostics.
3.
Electrical Noise
Table 31. Electrical Noise
Step Actions and Questions SUSPECT COMPONENTS v HVPS (Asm-Index: 12-11, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Assembly (Asm-Index: 12-4, page 575) v EP Cartridge (Asm-Index: 11-40, page 572) v Fuser Assembly (Asm-Index: 8-1, page 564) v Heater Assembly (Asm-Index: 9-5, page 567) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v High Harness Assembly (Asm-Index: 6-5, page 559) EXTERNAL NOISE a. Check if there is other electrical equipment, such as electrical generators, radio transmitters, or devices using electrical motors, within ten feet of the printer. b. Shut off the other electrical equipment, or relocate the printer at least twenty feet away from other devices. Is the Electrical Noise problem still present? AC GROUND 2. Check the AC wall outlet. Is the AC wall outlet correctly wired and grounded? Go to step 3 Have the customer repair the AC wall outlet Go to step 2 Verify the x. Also verify that the problem job prints. Yes No
1.
8.
DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page Go to step 9 559) Inspect the DTS and the TR wires. Are the wires connected properly? CAUTION: <2-25> High Temperature; switch off the printer and allow at least 40 minutes for parts in this area to cool before handling. Go to step 10
9.
HEATER ASSEMBLY (Asm-Index: 9-5, page 567) Inspect the cables of P142-1 and the right end of the Heater Rod. Are the cables attached properly? HVPS a. Remove the Controller Assembly (See page 535). Replace the HVPS (See page 532) Go to step 11
10.
b. Disconnect P/J15 from the MCU PWB (Asm-Index: 12-8, page 575). c. Run a Test Print (continuously approximately ten sheets). Do the Test Prints run normally? Replace the MCU PWB (See page 526 or 529)
Go to step 12
11.
Is the problem still present? Inspect all of the grounds in the printer. Are the grounds proper? Replace the Suspect Components
Verify the x. Also verify that the problem job prints. Repair the bad grounds
12.
13.
There is probably a conguration problem. Refer the System Adminstrator to Ethernet and Token Ring Quick Conguration Guide, G544-5499. Go to step 4
Reseat the IPDS SIMM. If that does not x the problem, install a new IPDS SIMM.
3.
Switch on the printer power. Wait for the READY message. Wait for the full 5 minutes (you may get an error code after the printer times out). Does READY appear within 5 minutes?
Return to Diagnostic Quick Path on page 28 with the new error code or symptom.
4.
6.
Look at the printer conguration page. Is each installed NIC indicated on Go to step 7 the printer conguration page? Can you print a NIC Cong Page for each installed NIC from the printer (TEST MENU/PRINT EN CONFIG or TEST MENU/PRINT TR CONFIG)? Go to step 8
7.
Go to step 9
8.
9.
The NIC that is not shown on the printer conguration page, or the Controller has a problem. v Power off. v Reseat the NIC. v Power on and wait for 5 minutes. Is the problem xed?
Verify the x. Also Go to step 10 verify that the problem job prints.
10.
12.
Feed Solenoid
Table 33. Feed Solenoid
Step Actions and Questions SUSPECT COMPONENTS v Feed Solenoid (Asm-Index: 4-8, page 555) v Feeder PWB (Asm-Index: 3-1, page 553) v MCU PWB (Asm-Index: 12-8, page 575) v Cassette Guide Assembly L (Asm-Index: 3-6, page 553), including the Feeder Harness (Asm-Index: 3-12, page 553) v Tray Harness (Asm-Index: 12-17, page 575) DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 1. FEED SOLENOID POWER SUPPLY a. Remove the Controller Assembly (See page 535) b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check the voltage between P/J20-A11 <=> P/J20-B1. Is there 24VDC between P20-A11 <=> P20-B1? Go to step 3 Go to step 2 Yes No
Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529)
3.
FEEDER PWB (Asm-Index: 3-1, page 553) a. Disconnect P/J201, P/J202 and P/J203 from the Feeder PWB (Asm-Index: 3-1, page 553). 4. b. Check for the continuity between P201 <=> P202 <=> P203 below: v P201-A1 <=> P202-A1 <=> P203-8 v P201-A8 <=> P203-9 Is the continuity on wires above between P201 <=> P202 <=> P203? PICK UP SOLENOID (Asm-Index: 6-17, page 559) 5. a. Leave P/J203 disconnected. b. Check the resistance between J203-8 <=> J203-9. Is there approximately 120 ohms resistance between J203-8 <=> P203-9?
Go to step 7
Go to step 6
Replace the Feed Replace the Solenoid (See Feeder Harness page 446)
7.
Replace the MCU Replace the PWB (See page Feeder PWB (See 526 or 529) page 420)
8.
9.
HVPS
Table 34. HVPS
Step Actions and Questions SUSPECT COMPONENTS v HVPS (Asm-Index: 12-11, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v CRU Guide Assembly L (Asm-Index: 11-30, page 572) v CRU Guide Assembly R (Asm-Index: 11-31, page 572) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v HVPS Harness (Asm-Index: 12-15, page 575) v EP Cartridge (Asm-Index: 11-40, page 572) v High Harness Assembly (Asm-Index: 6-5, page 559) CRU GUIDE ASSEMBLY L POWER SUPPLY a. Ensure that an EP Cartridge is installed. b. Inspect Spring contact on the CRU Guide Assembly L and the plate terminals on the EP Cartridge. Are the Spring contacting the plate terminals properly? CRU GUIDE ASSEMBLY L POWER SUPPLY a. Remove the HVPS (See page 532) while performing next step. 2. b. Inspect the Spring contact on the CRU Guide Assembly L and the HVPS during the removal of the HVPS. Does the Spring contact the HVPS properly? Go to step 3 Replace the CRU Guide Assembly L (See page 506). Go to step 2 Replace the CRU Guide Assembly L (See page 506) Yes No
1.
4.
9.
DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page Call technical 559) support (see Appendix D. a. Remove the Transport Chute Assembly (See page 468) Technical b. Disconnect the DTS and TR Plugs from the HVPS (Asm-Index: 12-11, Support on page 575) and from the Transport Chute Assembly. page 602). c. Check for the continuity between both ends of the DTS and TR wires. Is there continuity through the DTS and TR wires? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation)
10.
If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
LVPS
Table 35. LVPS
Step Actions and Questions SUSPECT COMPONENTS v LVPS Assembly (Asm-Index: 12-4, page 575) v MCU PWB (Asm-Index: 12-8, page 575) v LVPS Harness (Asm-Index: 12-14, page 575) LVPS ASSEMBLY (Asm-Index: 12-4, page 575) 1. a. Disconnect P/J121 and P/J126. b. Switch ON the Main Power. c. Check the voltage between P121-5 <=> P121-4 and P126-1 <=> P126-2. Is there 5VDC between P121-5 <=> P121-4, and P126-1 <=> P126-2? LVPS HARNESS (Asm-Index: 12-14, page 575) a. Switch OFF the Main Power. b. Disconnect P/J11. c. Check for the continuity between J11 <=> J121 as below: v J11-1 <=> J121-6 v J11-2 <=> J121-5 (+5V) v J11-3 <=> J121-4 v J11-4 <=> J121-3 v J11-5 <=> J121-2 v J11-6 <=> J121-1 (+24V) Is there continuity between J11 <=> J121? Go to step 3 Replace the LVPS Harness Go to step 2 Replace the LVPS Assembly (See page 521) Yes No
2.
Replace the MCU Notify customer or PWB (See page their electrician. 526 or 529)
4.
3.
6.
End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
2.
5.
Registration Sensor
Table 39. Registration Sensor
Step Actions and Questions SUSPECT COMPONENTS v Registration Sensor (Asm-Index: 7-6, page 562) v Registration Actuator (Asm-Index: 7-7, page 562) v Transport Chute Assembly (Asm-Index: 6-2, page 559) v MCU PWB (Asm-Index: 12-8, page 575) v High Harness Assembly (Asm-Index: 6-5, page 559) v LVPS Assembly (Asm-Index: 12-4, page 575) RESISTRATION SENSOR and ACTUATOR (Asm-Index: 7-6 and 7-7, page 562) a. Remove the Rear Tie Plate (part of Registration Sensor/Actuator on page 484). 1. b. Push up and then release the Registration Actuator and inspect the relative position with the detecting point of the Registration Sensor. Is the arm of the Registration Actuator away from the detecting point of the Registration Sensor when you push up the Actuator? Does the arm shield the detecting point of the Sensor when you release the Actuator? Go to step 2 Replace the Registration Sensor and/or Actuator (See page 484) Yes No
2.
3.
5.
Replace the Replace the High Registration Harness Sensor (See page Assembly 484)
7.
Toner Sensor
Table 40. Toner Sensor
Step Actions and Questions SUSPECT COMPONENTS v Toner Sensor Assembly (Asm-Index: 5-13, page 557) v MCU PWB (Asm-Index: 12-8, page 575) v Toner Sensor Harness (Asm-Index: 5-17, page 557) v Toner Relay Harness (Asm-Index: 12-18, page 575) v MSI Bracket Assembly (Asm-Index: 5-7, page 557) DANGER <1-16> The following procedures require that you work with power on. Follow the instructions under Working with Power On in Electrical Safety for IBM Customer Engineers, S229-8124. Do not touch moving parts. 1. TONER SENSOR POWER SUPPLY a. Remove the Controller Assembly (See page 535). b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB (Asm-Index: 12-8, page 575). c. Check the voltage between P/J22-1 <=> P/J22-3. Is there 24VDC between P/J22-1 <=> P/J22-3? CONTINUITY ON MCU PWB a. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575). b. Check for the continuity between P22-1<=> P21-1. Is there continuity between P22-1 <=> P21-1? Go to 24V Power Replace the MCU Supply to MCU PWB (See page on page 144 526 or 529) Go to step 3 Go to step 2 Yes No
2.
4.
7.
Print a Cong Page (see page 250). Is IPDS indicated on the Cong Page? 2.
Verify that there is enough memory for IPDS jobs. Refer to the IBM InfoPrint 20: Users Guide for memory requirements. Go to step 3. Go to step 4
Reseat the IPDS SIMM. If that does not x the problem, install a new IPDS SIMM.
Switch on the printer power. Wait for the READY message. 3. Does READY appear within 5 minutes?
Return to Chapter 1. Getting Started on page 25 with the new error code or symptom.
5.
Go to step 6
6.
Can you print a NIC Cong Page from the Test button on the back of the Go to step 7 NIC? When a job is sent, does the printer operator panel indicate its arrival with a message such as TX IPDS or CX IPDS? The cabling and NIC are OK. Suspect a problem with menu settings, the IPDS SIMM, or the controller SIMM/board.
Go to step 10
Go to step 8
7.
8.
The NIC is Go to step 9 receiving polls from the system. Suspect a job or conguration problem. Refer the System Administrator to the IBM Network Printers: Twinax and Coax Conguration Guide or Tech Support. Note: If the Share light is also on when the printer is READY, install a new NIC.
9.
There is probably Replace the NIC a network cabling problem or a conguration problem. Refer the System Administrator to the IBM Network Printers: Twinax and Coax Conguration Guide or Tech Support (see Appendix D. Technical Support on page 602). Verify the x. Also verify that the problem job prints. If there is only one NIC in the printer, go to step 11. If you have another NIC, you can try swapping NIC positions on the controller to isolate NIC vs Controller.
10.
There is a problem with the NIC or Controller v Power off. v Reseat the NIC v Power on and wait. Is the problem xed?
12.
End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation) If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
Print Quality
Background
PROBLEM: There is toner contamination on all or part of the page. The contamination appears as a light gray dusting.
hc2m211F
1.
3.
6.
Black Prints
PROBLEM: The entire print is black. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.
hc2m203F
1.
4.
Blank Prints
PROBLEM: The entire print is blank. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.
hc2m202F
1.
2.
GROUND OF THE METAL GROUNDING PLATE 3. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Grounding Plate and the printer frame? 4. BTR ASSEMBLY (Asm-Index: 6-1, page 559) Is the BTR intact, not contaminated? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF power halfway through the print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the drum just before the transfer area (BTR). Is the image on the drum completely developed, with sharp, black, easily read areas?
Go to step 4
Go to step 5
Go to step 6
5.
7.
hc2m215F
Damaged Print
PROBLEM: The printed page comes out of the printer either wrinkled, creased, or torn.
hc2m213F
2.
6.
EP CARTRIDGE a. Install a new EP Cartridge. b. Run a Test Print. Is the print still damaged? End of diagnostic and a problem remains v Exchange the remaining suspected FRUs, one at a time. v Check the following, suspecting an intermittent problem: All connectors and wiring associated with the suspected FRUs All ground connectors (see Printer Safety Inspection on page 13) Environmental conditions (temperature, humidity, ventilation)
Go to step 7
7.
If the printer still fails, return to Diagnostic Quick Path on page 28 and dene the problem again. If you do not nd a solution, call your next level of support (see Appendix D. Technical Support on page 602).
hc2m214F
1.
4.
hc2m201F
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Verify the x. Also Go to step 3 verify that the problem job prints.
CONTINUITY OF THE METAL GROUNDING PLATE 5. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Plate Grounding Plate and the printer frame?
Go to step 6
8.
10.
Residual Image
PROBLEM: There are ghost images on the page. The images may be either ghosts of the previous page or parts of the page being printed.
hc2m210F
5.
6.
Skewed Image
PROBLEM: The printed image is not parallel with the sides of the page.
hc2m212F
1.
f. Reprint the problem image. Is the problem still present? PAPER PATH 2. Inspect the paper path between the feed tray and the exit tray for contamination or obstructions. Is the paper path free of obstructions? PAPER PATH ROLLS Go to step 4 a. Inspect all of the rolls along the paper path, between the feed tray and the exit tray, for contamination, wear, or damage. b. Ensure that the pinch rolls turn freely and that the spring pressure is even. Are the paper path rolls free of contamination, wear, or damage? Go to step 3 Remove obstructions or contamination from the paper path. Replace the damaged or worn roll. (See Chapter 6. Removal Procedures, Adjustments on page 394)
3.
4.
5.
Spots
PROBLEM: There are spots of toner randomly scattered across the page.
hc2m209F
1.
Verify the x. Also Go to step 2 verify that the problem job prints.
3.
4.
Streaks, Horizontal
PROBLEM: There are black lines running horizontally across the page. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.
hc2m207F
1.
3.
CONTINUITY OF THE METAL GROUNDING PLATE 4. Check for the continuity between the Metal Grounding Plate and the printer frame. Is there continuity between the Grounding Plate and the Printer Frame? BTR ASSEMBLY (Asm-Index: 6-1, page 559) 5. Inspect the BTR Assembly for contamination and wear. Is the BTR free of contamination and wear? IMAGE DEVELOPMENT PROCESS a. Generate a Test Print and switch OFF printer power halfway through print cycle. b. Carefully remove the EP Cartridge and inspect the toner image on the Drum just before the transfer area (BTR). Is the image on the Drum completely developed; with sharp, black, easily read areas and no horizontal streaks?
Go to step 5
Go to step 6
Replace the BTR Assembly (See page 466) Go to HVPS on page 159
Go to step 7
6.
8.
Streaks, Vertical
PROBLEM: There are black lines running vertically along the page. Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Since there is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. The symptom with no DRAM is light, solid rectangles on the top line of the operator panel. After several minutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of this problem, see Operator Panel, Controller, and Power Problems on page 135.
hc2m206F
1.
6.
Unusual Patterns
PROBLEM: Light gray background, with large areas covered with random dark spots. This is usually caused by charging problems during printing.
hc2m216F
Voids
PROBLEM: There are areas of the image that are extremely light or missing. These missing areas form localized spots to small areas of the page.
hc2m208F
1.
3.
5.
Voids, Horizontal
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands that run horizontally across the page, parallel with the direction of paper travel.
hc2m205F
1.
5.
7.
Voids, Vertical
PROBLEM: There are areas of the image that are light or missing. These missing areas form wide bands that run vertically along, in the direction of paper travel.
hc2m204F
1.
6.
Status Messages
Printer status messages are listed alphabetically. COLD RESET A4 Meaning: The printer is powering up and resetting all menu values to the factory defaults. The A4 paper group is the default. Action: None required; however, restore any unique settings for the printer (such as the default tray). COLD RESET LTR Meaning: The printer is powering up and resetting all menu values to the factory defaults. The LTR paper group is the default. Action: None required; however, restore any unique settings for the printer (such as the default tray). CONTEXT SAVE ADJUSTED Meaning: The printer is congured to use the context saving option (PCL SAVE and PS SAVE under the Memcong Menu); however, due to a conguration change, the printer no longer has enough memory to support context saving. Action: Press Continue. To restore context saving, have the customer add more memory to the printer. CONTEXT SAVE CHANGE Meaning: The values for the PCL SAVE or PS SAVE items under the Memcong Menu have been changed. Action: Press the Continue key to accept the new values and continue printing. DSK FMT RESTART Meaning: The printer is restarting to include the hard drive in its conguration. Action: None required.
+ FORMAT DISK/- IGNORE DISK Meaning: You are powering up with an unformatted hard drive, or you selected the FORMAT DISK action on the Test Menu. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to continue as if there were no hard drive installed. FLUSHING... Meaning: The printer is canceling a PCL5e or PostScript job. Action: None required. FORMATTING Meaning: The printer is formatting the hard disk drive. Action: None required. F/W xxxxxxx Meaning: Firmware error (xxxxxxx can be any alphanumeric value). Action: Power the printer off, wait ten seconds, and power the printer back on. If problems persist, call for technical support. Note: When rmware errors occur, the printer might also print an error page. If the printer does print an error page, save it so you can tell technical support. I/O INITIALIZING Meaning: The network interface card is initializing. Action: Normally none. If the message remains on the display for more than 5 minutes and nothing prints, go to Ethernet / Token-Ring NIC Printing Problems on page 150 or Twinax / Coax NIC Printing Problems on page 179. Note: If more than one Network Interface Card is installed, remove them one at a time to determine which card is causing the problem.
IBM INFOPRINT 20 Meaning: The printer power has just been switched on. Action: Normally none. If the message remains on the display and nothing prints, wait three minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to Operator Panel, Controller, and Power Problems on page 135. - IGNORE DISK/+ FORMAT DISK Meaning: You are powering up with an unformatted hard drive, or you selected the FORMAT DISK action on the Test Menu. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to continue as if there were no hard drive installed. IPDS COAX Meaning: The printer is receiving IPDS data through the coax interface. Action: None required. IPDS ETHERNET Meaning: The printer is receiving IPDS data through the Ethernet interface. Action: None required. IPDS TOKEN-RING Meaning: The printer is receiving IPDS data through the token-ring interface. Action: None required. IPDS TWINAX Meaning: The printer is receiving IPDS data through the twinax interface. Action: None required. JOB QUEUED Meaning: An informational page is queued for printing. Action: If the online indicator is off, press the Online key.
Chapter 2. Diagnosing Problems 241
KEY NOT VALID Meaning: You pressed a key that is not valid. Action: Press another key. In some instances, you may need to press the Online key to use other keys such as the Menu key. MEMCONFIG CHANGE Meaning: You changed a value on the Memory Conguration (Memcong) Menu. Action: Press the Continue key to reboot the printer so the new value can take effect. MEMCONFIG CHANGE 1200 DPI UNAVAIL Meaning: You turned on context saving (PCL SAVE or PS SAVE) on the Memory Conguration (Memcong) Menu. 1200 dpi emulation is no longer available because there is not enough memory. Action: Press the Continue key to reboot the printer so the new value can take effect. To enable 1200 DPI emulation, Have the customer add more memory or turn context saving off. MENU LOCKED Meaning: The system administrator has locked the menu. You can view menu settings but you cannot change them. Action: None required. MRT COMPRESSION Meaning: The printer is compressing the page image it is printing because it does not have enough memory to print the page without compression. Action: None required. NEW VALUES AT NEXT BOUNDARY Meaning: You have taken the printer offline while a job was printing to change a menu value. The new value might not take effect until the next job boundary. Different data streams, in particular SCS, dene job boundaries in different ways, so it may take a while for the new value to take effect. Action: None required. If problems occur, make sure you take the printer offline to change menu values only when no jobs are printing (the printer is in READY state).
Chapter 2. Diagnosing Problems 242
NONIPDS COAX Meaning: The printer is receiving SCS or DSC/DSE data through the coax interface. Action: None required. NONIPDS TWINAX Meaning: The printer is receiving SCS data through the twinax interface. Action: None required. OFFLINE Meaning: The printer is offline. Action: Press the Online key to make the printer active. ONLINE HEX PRT Meaning: The printer is performing a hexadecimal dump. Action: None required. PAGES:nnnn Meaning: This is a response to the PAGE COUNT item on the Machine Info Menu, where nnnn is the number of pages the printer has printed. Action: None required. PCL ETHERNET Meaning: The printer is receiving PCL5e data through the Ethernet interface. Action: None required. PCL PARALLEL Meaning: The printer is receiving PCL5e data through the parallel interface. Action: None required. PCL TOKEN-RING Meaning: The printer is receiving PCL5e data through the token-ring interface.
Action: None required. PJL PARALLEL Meaning: The printer is receiving or sending PJL information through the parallel interface. Action: None required. PLEASE WAIT Meaning: The printer is processing data and cannot immediately respond to a request. Action: Wait until the message clears. If the message remains and processing on the host appears to have stopped, power off the printer, wait ten seconds, and then power on the printer. POWER SAVER ON Meaning: The printer is in power-saving mode and has temporarily shut off power to certain of its components. Power will be restored as soon as a job is submitted. Action: None required. PS ETHERNET Meaning: The printer is receiving PostScript data through the Ethernet interface. Action: None required. PS PARALLEL Meaning: The printer is receiving PostScript data through the parallel interface. Action: None required. PS TOKEN-RING Meaning: The printer is receiving PostScript data through the token-ring interface. Action: None required. READY Meaning: The printer is ready to receive data. Action: None required.
+ REALLY FORMAT / - IGNORE DISK Meaning: You have asked to format the hard drive. Action: Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously to cancel the formatting. RECONFIGURING MEMORY Meaning: The printer has received a print job that requires it to adjust memory settings for the current page. Action: No action is required. The printer recongures its memory settings to print the current page. Afterward, its settings revert to normal. RESETTING PRINTER Meaning: The printer is resetting to its defaults. Action: None required. RESTORING DEFAULTS Meaning: The printer is restoring the defaults. Action: None required. SWITCHING TO IPDS Meaning: The printer is switching to IPDS. Action: None required. SWITCHING TO PCL Meaning: The printer is switching to PCL5e. Action: None required. SWITCHING TO PS Meaning: The printer is switching to PostScript. Action: None required.
WAIT FOR IDLE PRINTER Meaning: You attempted to print from the Test Menu while the printer was processing PCL, PostScript, or IPDS data. Action: When a port timeout occurs for the data stream (PCL5e, PostScript, or IPDS), the READY message appears on the operator panel. Wait for the READY message and then try printing again. WARMING UP Meaning: The printer is warming up. When it is warm, it displays the READY message. Action: None required. If the message seems to appear too frequently, change the value for the power-saving mode to a larger value. If the message remains on the display and nothing prints, wait three minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to Operator Panel, Controller, and Power Problems on page 135.
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.249 .250 .251 .251 .251 .252 .253 .254 .254 .255 .256 .257 .257 .257 .258 .259 .261 .267 .269 .271 .273 .275 .277 .279 .281 .283 .285 247
D63 MOTOR D CW (Duplex Motor Runs CW) . . . . D64 MOTOR D CCW (Duplex Motor Runs CCW) . . . D68 HCF MOTOR (HCF Transport Motor). . . . . . . FACTORY ADJ MENU . . . . . . . . . . . . . . . . . . A01 Reg Top 1 (Leading Edge Registration, Tray 1) . A03 Reg Top 2 (Leading Edge Registration, Tray 2) . A05 Reg Top 3 (Leading Edge Registration, Tray 3) . A07 Reg Top A (Leading Edge Registration, Aux. Tray) A09 Reg Left 1 (Left Edge Registration, Tray 1). . . . A11 Reg Left 2 (Left Edge Registration, Tray 2) . . . . A13 Reg Left 3 (Left Edge Registration, Tray 3). . . . A15 Reg Left A (Left Edge Registration, Aux. Tray) . . A21 Fuser Temp (Adjustment) . . . . . . . . . . . . . S/N = 00-00000 (Serial Number) . . . . . . . . . . . Menu Items Not Described . . . . . . . . . . . . . . . .
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.287 .289 .291 .293 .296 .297 .298 .299 .300 .301 .302 .303 .304 .305 .306
v v v v v v
Online to toggle the printer online or offline. Menu to scroll through menus. Item to scroll through menu items. Value to scroll through values for a menu item. Shift to reverse the scroll direction. Enter to accept a menu item or value selection.
Conguration Page
1. 2. 3. 4. Press Press Press Press Online to take the printer offline. Menu. The message TEST MENU appears. Item. The message CONFIG PAGE appears in the second line. Enter to print the conguration page.
Notes: 1. The conguration pages print from the PAPER MENU/SOURCE. 2. To print continuous conguration pages, press Item until CONTINUOUS TEST appears, then press Enter. To stop, press Cancel Print and wait for up to 10 pages. 3. To print duplex continuous conguration pages, set PAPER MENU/DUPLEX=ON. 4. If the serial number printed on the conguration page does not match the printer serial number, see S/N = 00-00000 (Serial Number) on page 305. (See Figure 5 on page 363 for the location of the printer serial number.)
Cold Reset
The following procedure resets all values in printer NVRAM to factory defaults, and clears the error log. 1. Print a conguration page (see Conguration Page on page 250). 2. Switch off printer power. 3. Do the following: For the LTR (letter) paper group: Press and hold the Online key while switching on printer power. COLD RESET LTR appears in the message display. For the A4 paper group: Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in the message display.
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.
Counters
The Machine Info Menu also displays information about printer supply usage. From the Machine Info Menu, select the desired counter:
Machine Info Menu Item PAGE COUNT ERROR LOG TONER COUNTER Description Displays the number of pages the printer has printed. Displays the error log. Use the Value key to scroll through the list. Displays the EP cartridge count. IBM recommends resetting this counter whenever you change toner cartridges. To reset the counter: 1. Simultaneously press the Shift and Value keys. 2. Press the Enter key. Displays the fuser counter. IBM recommends resetting this counter whenever you change the usage kit. To reset the counter: 1. Simultaneously press the Shift and Value keys. 2. Press the Enter key.
FUSER COUNTER
Service Mode
The service mode consists of two service menus: the DIAGNOSTICS MENU and the FACTORY ADJ MENU. To display a service menu: 1. Power OFF the printer. 2. Turn on the printer power while pressing Item and Value simultaneously for a few seconds. Wait until the message DIAGNOSTICS MENU appears. 3. Press Menu to select the service menu (DIAGNOSTICS MENU or FACTORY ADJ MENU). To 1. 2. 3. select a test or item in the DIAGNOSTICS MENU or FACTORY ADJ MENU: Press Item to scroll through the tests or items. Press Enter when you reach the test or item you want to run. Press Cancel Print to temporarily stop an action test, such as a motor running test. Then press Enter to restart the same test.
DIAGNOSTICS MENU
D01 TEST PRINT
Prints a test matrix page from Tray 1. Before performing this test, make sure Tray 1 has paper. There is no error reporting with this test. To run D01 TEST PRINT: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D01 TEST PRINT displays. Press Enter to begin printing from Tray 1. After the print completes, press Item to step to another item in the DIAGNOSTICS MENU
See Test Prints on page 251 for more information on running test prints.
Output Tests
The output tests fall into two groups: v Displaying the fuser temperature control setting and the current fuser temperature v Actuating components Once the unit starts executing an output test, the only diagnostic codes accessible are those for output tests. It is thus impossible to break out of the output test mode. Turning the interlock switch off is another way of terminating the display of the accumulated print count. The output tests permit the parallel operation of multiple components.
The following chart lists the temperature code settings and the corresponding temperature ranges.
Table 57. Fuser Temperature Codes
Code Temperature Code Range [Normal Temp./High Temp.] (Hexadecimal) Fuser Temperature [Normal Temp./High Temp.] (C) Approximate 0 1 2 3 4 5 6 7 8 9 A B C D E F C2 / B2 BF / AF BC / AC B9 / A9 B6 / A6 B3 / A3 B0 / A0 AD / 9D AA / 9A A7 / 97 A4 / 94 A1 / 91 9E / 8E 9B / 8B 98 / 88 95 / 85 155 / 172 158 / 175 162 / 178 165 / 181 168 / 184 171 / 187 174 / 190 177 / 193 180 / 196 183 / 199 186 / 202 189 / 205 192 / 208 195 / 211 198 / 215 201 / 218
To run D21 SENSOR TEST: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Press Item to step through the tests or items. Stop pressing Item when D21 SENSOR TEST displays. Press Enter to begin test. Manually activate and deactivate the sensor or the switch you want to test. If a sensor or switch is functioning correctly, SENSOR OK displays. If the sensor is not functioning correctly, Activate Sensor continues to display. 6. To exit this test activate a sensor that functions correctly, then press Item to step to another item in the DIAGNOSTICS MENU. Note: See Figure 3 on page 265 and Figure 4 on page 266 for the locations of the following items.
Exit sensor
Procedure Disconnect P/J171 at the CRU sensor assembly or P/J17 at the MCU; this ensures that the laser will not turn on if you accidentally activate the CRU sensor. If the duplex option is installed, you can open the duplex cover to disable the laser. With the interlock switch on, install and remove an EP cartridge containing toner, or activate with a non-magnetic metal tool. With the duplex unit lower cover closed, open and close the duplex unit upper cover to turn the duplex cover switch 1 on and off. With the duplex unit upper cover closed, open and close the duplex unit lower cover to turn the duplex cover switch 2 on and off. Open the duplex unit upper cover. Use your hand or other means to move the duplex pass sensor actuator and thus turn the duplex pass sensor on and off. Use your hand or other means to move the DUP stack actuator to switch the DUP stack sensor between its no paper and paper positions. Open the HCF rear cover. Override the left and right cover open switches. Cover and uncover the sensor. Cannot be tested with D21. Remove the left hand side plate. Depress the switch. Remove the front cover. Depress the switch. Open the HCF rear cover on the left side only. Opening the cover will change the state of the switch. Open the HCF rear cover on the right side only. Opening the cover will change the state of the switch. With the HCF drawer pulled out and the elevator in the down position, depress both the tray set sensor 1 and tray set sensor 2. Activate D21 and release tray set sensor 1. (Do not allow the bottom plate to rise near the top of the drawer. Damage will occur by not coming in contact with the upper limit switch).
Duplex cover switch 1 Duplex cover switch 2 Duplex pass sensor DUP stack sensor HCF Exit sensor HCF Lower position sensor HCF size sensor HCF Near empty sensor HCF left hand cover open switch HCF right hand cover open switch HCF tray set sensor 1
Procedure Cannot test with D21 With the elevator in the down position, open the front door and activate D21. Reach inside and push up on the feed roller bracket until you hear a click. This will activate the upper limit switch. Push the actuator up into the paper level sensor. Push up on the paper out sensor. The paper out actuator and sensor are part of the feed roller bracket assembly.
Pinch Roll
Exit Roll Assembly Exit Sensor CRU Switch Control Assembly (Console Assembly) Exit Sensor Full Stack Sensor Exit Actuator Fuser Assembly
Toner Sensor
Registration Sensor
Registration Sensor
Pick Up Roll
Registration Actuator
Fuser Cover
Interlock Actuator
FRONT
Fuser Cover Switch Interlock Switch
Size Actuator
Feeder PWB
Feed Roll
hc2m980F
Fan
MCU
FRONT
hc2m993F
To run D23 TEST FAN: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D23 TEST FAN displays. Press Enter to begin test. Verify that when you press Enter, the fan is running at high speed. Verify that the fan is running at high speed from the noise that it makes or from the wind pressure. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. Note: The fan runs at low speed whenever the power is on. It switches to high speed when the main motor is on. This test switches the fan from low speed to high speed.
FRONT
MCU PWB
Electromagnetic Turn Roll Clutch (Tray 1) Electromagnetic Turn Roll Clutch (Tray 2) Electromagnetic Turn Roll Clutch (Tray 3)
hc2m985F
To run D41 CLUTCH TR: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D41 CLUTCH TR displays. Press Enter to begin test. Verify that when you press Enter, the turn roll clutch actuates. Conrm clutch operation by listening for the slight click of operation or manually rotating the corresponding driven rollers (rubber registration roll and turn roll assembly) to conrm that they are no longer free, but xed to the drive system. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
FRONT
hc2m986F
To run D43 CLUTCH REG: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D43 CLUTCH REG displays. Press Enter to begin test. Verify that when you press Enter, the registration clutch actuates. Conrm clutch operation by listening for the slight click of operation or manually rotating the corresponding driven rollers (rubber registration roll and turn roll assembly) to conrm that they are no longer free, but xed to the drive system. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
hc2m026F
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.
hc2m026F
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.
MCU PWB
Pick Up Solenoid
hc2m983F
To run D50 SOL TRAY A: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D50 SOL TRAY A displays. Press Enter to begin test. Verify that when you press Enter, the AUX feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. The solenoid may now be in a pre-pick condition. Remove paper from the Auxiliary Tray and switch the printer off, and then on to reset the solenoid (if you do not remove paper you may get a 24 PAPER JAM when the motor is tested during power up).
FRONT
D51
MCU PWB
D52
Feed Solenoid
D53
Feed Solenoid
hc2m984F
Feed Solenoid
To run D51 SOLENOID TRAY1: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D51 SOLENOID TRAY1 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 1 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
FRONT
D51
MCU PWB
D52
Feed Solenoid
D53
Feed Solenoid
hc2m984F
Feed Solenoid
To run D52 SOLENOID TRAY2: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D52 SOLENOID TRAY2 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 2 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
FRONT
D51
MCU PWB
D52
Feed Solenoid
D53
Feed Solenoid
hc2m984F
Feed Solenoid
To run D53 SOLENOID TRAY3: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). 2. 3. 4. 5. Repeatedly press Item to step through the tests or items. Stop pressing Item when D53 SOLENOID TRAY3 displays. Press Enter to begin test. Verify that when you press Enter, the Tray 3 feed solenoid actuates. Conrm solenoid operation by listening for the slight click of operation or watching for the rotation of the corresponding shaft or roller when the power is turned off and on after the execution of the diagnostic routine. 6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.
FRONT
hc2m987F
To run D60 DRIVE MOTOR MAIN: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D60 DRIVE MOTOR MAIN displays. Press Enter to begin test. Verify that when you press Enter, the main motor switches on and rotates. Conrm motor operation by listening for the sound of operation or by visual observation. 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. 2. 3. 4. 5.
Duplex Motor
hc2m823F
To run D63 MOTOR D CW: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D63 MOTOR D CW displays. Press Enter to begin test. Verify that when you press Enter, the duplex motor switches on and rotates. Conrm motor operation by listening for the sound of operation or by visual observation. 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. 2. 3. 4. 5.
Duplex Motor
hc2m823F
To run D64 MOTOR D CCW: 1. Enter the DIAGNOSTICS MENU (See Service Mode on page 256). Repeatedly press Item to step through the tests or items. Stop pressing Item when D64 MOTOR D CCW displays. Press Enter to begin test. Verify that when you press Enter, the duplex motor switches on and rotates in a counter-clockwise direction (Open the cover and override the interlock to watch the motor rotate). 6. You can press Cancel Print to temporarily stop the test, and then press Continue/Enter to restart the test. 7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU. Conrm motor operation by listening for the sound of operation or by visual observation. 2. 3. 4. 5.
1
hc2m042F
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.
307
Signal names for the MCU Toner Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the MCU Toner Sensor path. . . . . . . . . . . . . . . . . . MCU DUPLEX I/F PWB FUSER COVER SWITCH or MCU FUSER COVER SWITCH . . . . Signal names for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path . . . . . . . . . Pin numbers and voltage level for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path Signal names for the MCU FUSER COVER SWITCH path . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage level for the MCU FUSER COVER SWITCH path. . . . . . . . . . . . CONTROLLER CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Controller Control Panel path . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the CONTROLLER CONTROL PANEL path . . . . . . . . . CONTROLLER MCU and LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Controller MCU path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Controller MCU path . . . . . . . . . . . . . . . . . . . Signals between the Controller and the MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MCU Feeder PWB Feeder PWB Feeder PWB Feed Solenoid, No Paper Sensor, and Electromagnetic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the Feeder PWB Feeder PWB path . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Feeder PWB (Feeder1) Feeder PWB (Feeder2) path . . . Pin numbers and voltage levels for the Feeder PWB (Feeder2) Feeder PWB (Feeder3) path . . . Detection of the Feeder conguration through the FEEDER CHECK signal. . . . . . . . . . . . . . MCU Duplex I/F PWB Duplex PWB and Fuser Cover Switch Duplex PWB Dup Stack Sensor, Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor . . . Signal names for the Duplex I/F PWB Duplex PWB path . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Duplex I/F PWB Duplex PWB path . . . . . . . . . . . . Signal names for the Duplex PWB Offset Motor path . . . . . . . . . . . . . . . . . . . . . . . Pin numbers and voltage levels for the Duplex PWB Offset Motor path . . . . . . . . . . . . . . HCF LVPS Components, HCF LVPS FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . Signal names for the HCF LVPS Components . . . . . . . . . . . . . . . . . . . . . . . . . . . Signal names for the HCF LVPS FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . . . .
.331 .331 .332 .333 .333 .333 .333 .334 .335 .336 .337 .338 .338 .339 .342 .344 .345 .346 .347 .349 .350 .351 .351 .352 .353 .354 .356
Pin numbers and voltage levels for the HCF LVPS Components. . . . . . . . . . . . . . . . . . . .357
OPTIONAL
P/J 114
TURN CLH
P/J 113
P/J206 P/J205
SOS
MOT
DB CR DTS TR
NO PAPER
P/J 203
FEEDER3
P/J204
HVPS
P/J 151
FEED SOL
P/J904
MAIN MOT
M
P/J 171
P/J221 P/J922 P/J222
MCU
P201 P207
OPTIONAL
OCT MOT
/DUP
/DUP
DUP SNS
CRU SNS
P/J 17
TURN CLH
P202
P/J206 P/J205
M
P/J 196 P/J 192 P/J 193 P/J 198
M
P/J 197 P/J 195
TONER SNS
P/J 22
NO PAPER
P/J 203
FEEDER2
P/J204
P/J 186
P/J184
DUPLEX PWB
P/J187
REG CLH REG SNS NOP SNS AUX AUX P182 P/J 132
P/J131
FEED SOL
P/J904
P183
P/J937
P/J137
P/J135
P/J935
P/J206 P/J205
NO PAPER
P/J 203
FEEDER1
P/J204
P/J P/J
FEED SOL
P/J904
P201
P/J143
P/J943
EXIT SENSOR
P/J 145
P/J 942
J130
P/J 144
TEMPERATURE SENSOR
HEATER ROD
THERMOSTAT THERMAL FUSE
P/J11
INTERLOCK SWITCH
FUSER
COVER SWITCH
P/J 126
HC2M994F
Wiring and Signal Description between Components MCU LVPS INTERLOCK SWITCH and FANs
INTERLOCK SW
P/J21
2 1
24VDC 24VDC
P/J123
LVPS
P/J11
1 2 3 4 5 6 RTN 5VDC SG /HEAT(TTL) FAN ALARM(TTL) /FAN FAST ON(L)24VDC
P/J121
6 5 4 3 2 1
FG
1 2 3
1 2 3
P/J122
FAN ALARM(TTL)
MCU
FAN ON
P124
RTN
AC
hc2m995F
FG
MAIN FAN
MCU
1 2 3
P/J14 8 7 6 5 4 3 2 1
5VDC
EXIT SENSOR
P/J144
1 2 3 TEMPERATURE SENSOR
HEAT ROLL
AC L HEATER ROD AC N
THERMOSTAT THERMAL FUSE
4 3 2 1
AC L AC N
LVPS
HEATER CONTROL
L N
FG
AC
hc2m996F
FG
FG
Pin numbers and voltage levels for the MCU Fuser Assembly path
P14 3 5 8 P142 B2 A4 A1 P942 B2 A1 A4 P144-1 P943-1 P145-1 P143-2 Signal Name /EXIT (TTL) TEMP. /FULL (TTL) Signal Direction MCUFuser MCUFuser MCUFuser Trigger Level * Level High Level TTL * TTL Low Level TTL * TTL Analog Note
MCU ROS and CRU SENSOR ASSEMBLY (CRU SWITCH and LD SWITCH)
ROS
P/J114
1 2 3 4 5 6 24VDC RTN /RMOT ON(TTL) /SP11(TTL) /SP12(TTL)
P/J12
15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
5VDC
MCU
MOT
P/J113
1
5VDC /SOS(TTL) SG
SOS
2 3
P/J112
1 2 3
LD
4 5 6 7
P/J17
5VDC-LD
NO CRU
1
5VDC
SG
P/J171
CRU SENSOR
Pin numbers and voltage levels for the MCU ROS path
Signal Direction M: MCU, L: LD S: SOS P112, P113, and P114 Signal Name P114-3 P114-5 P114-6 P113-2 P112-1 P112-3 P112-4 P112-5 P112-7 /RMOT ON (TTL) /SP11 (TTL) /SP12 (TTL) /SOS (TTL) 5VDC-LD VL1 VL2 MO /P. DATA (TTL) SM: Scanner Motor R: ROS PWB MCUScanner Motor MCUROS PWB MCUROS PWB MCUSOS MCUL MCUL MCUL MCUL MCUL Trigger Level Level Level Level Level High Level TTL TTL TTL TTL 5VDC * * * TTL Low Level TTL TTL TTL TTL 0V * * * TTL 0 3.5 V 0 3.5 V 0.7 1.4 V
P11 13 12 11 9 7 5 4 3 1
Note
MCU HVPS EP CARTRIDGE (BCR and MAG. ROLL), BTR, and DETACK SAW
CRU GUIDE ASSEMBLY L EP CARTRIDGE
DB
CR
HVPS
DRUM
DETACK SAW
DTS
BTR
TR
TRANS.CHUTE ASSEMBLY L
1 3 1 2 11 1 0 9 8 7 6 5 4 3 2 1
P/J151
DTS-D/A
BTR-D/A
TRMO-V
TRMO-I
24VDC
DB-AC
RTN
1 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3
P/J15
MCU
hc2m998F
Pin numbers and voltage levels for the MCU HVPS path
P15 3 4 5 6 7 8 9 10 11 12 13 P151 11 10 9 8 7 6 5 4 3 2 1 Signal Name DB-AC /DB-DC ON(L) 24VDC /CR-DC ON(L) 24VDC /CR-AC ON(L) 24VDC /DTS ON(L) 24VDC /TR(+) ON(L) 24VDC TR ON(L) 24VDC TRMO-I TRMO-V BTR-D/A DTS-D/A Signal Direction MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS MCUHVPS Trigger Level Level Level Level Level Level Level Level Level Level Level High Level TTL 24V 24V 24V 24V 24V 24V * * * * Low Level TTL 0V 0V 0V 0V 0V 0V * * * * Analog Analog Analog Analog Note
MCU REG. CLUTCH, REG. SENSOR, PICK UP SOLENOID, and AUX TRAY NO-PAPER SENSOR
MCU
P/J131
P/J13
1 2 3 4 5 6 7 8
P.UP SG /REGIN(TTL)
REGISTRATION SENSOR
P/J132
P/J135 P/J935
1 2
2 1
9 10
3 2 1
hc2m999F
Signal names for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path
Signal Name REG. ON(L) 24VDC /REG. IN (TTL) /NO PAPER0 (TTL) PICK UP ON(L) 24VDC Description Registration Clutch control signal. The Registration Clutch is activated when this signal is Low, and deactivated when High. Signal from the Registration Sensor. This signal is Low when the Registration Sensor is activated. Signal from the Aux Tray No-Paper Sensor (Front Tray). This signal is Low when the SI No-Paper Sensor is activated. Pick Up Solenoid control signal. The Pick Up Solenoid is activated when this signal is Low, and deactivated when High.
Pin numbers and voltage levels for the MCU REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper Sensor path
Signal Direction M: MCU, RC: Reg. Clutch RS: Reg. Sensor AT: Aux Tray No-Paper Sen. P13 2 5 8 10 P131-1 P132-1 P137-1 P935-1 Signal Name REG. ON(L) 24VDC /REG. IN (TTL) /NO PAPER0 (TTL) PICK UP ON(L) 24VDC FS: Feed Solenoid MRC MRS MAT MFS Trigger Level Level Level Level High Level TTL 24V 24V 24V Low Level TTL 0V 0V 0V
MCU FEEDER1 PWB FEED SOLENOID, CST NO-PAPER SENSOR, and ELECTROMAGNETIC CLUTCH
ELECTROMAGNETIC CST NO PAPER FEED SOLENOID SENSOR CLUTCH
3 2 1
/NO PAPER1 (TTL)
4 3 2 1
P.UP SG
904
P/J203
1 2 3 4 5 6 7 8 9
MCU
P/J20
PSIZE3 (TTL) A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11 PSIZE1 (TTL) /FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK 5VDC 24VDC RTN SG OPTION /NO PAPER2 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) N.C.
P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 SW4 SW3 SW2 SW1 PAPER SIZE SWITCH SIZE SENSE 24VDC
24VDC
24VDC
A B Y C
W
5VDC
P207 P/J202
1 2 N.C. 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
F
24VDC
A10 A9
A8 A7 A6 A5
A4 A3 A2 A1 B10 B9 B8
D X Z F
B7 B6 B5 B4
B A
B3 B2 B1
Z Y X w
FEEDER1
5VDC
5VDC
hc2m800F
PSIZE1 (TTL)
/FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK OPTION /NO PAPER2 (TTL) /SIZE 2BIT (TTL)
Signal Name /SIZE 4BIT (TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL)
Description Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 1, 2 or 3 signal. This signal is Low when the Paper Size Switch 4 is activated. Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) is activated when this signal is Low, and deactivated when High. Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutch is activated when this signal is Low, and deactivated when High. Selects the Paper Size Switches of Feeder 2. When this signal is High, the On or Off states of the Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE 1BIT to SIZE 4BIT.
Pin numbers and voltage levels for the MCU FEEDER1 PWB path
Signal Direction P20 A1 A2 A3 A4 A5 A6 A7 A8 A9 B3 B4 B6 B7 B8 B9 B10 P201 A11 A10 A9 A8 A7 A6 A5 A4 A3 B10 B9 B7 B6 B5 B4 B3 Signal Name PSIZE3 (TTL) PSIZE1 (TTL) /FEED3 ON(L) 24VDC /FEED1 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) /NO PAPER1 (TTL) FEEDER CHECK OPTION /NO PAPER2 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) M: MCU, F: Feeder1 MF MF MF MF MF MF MF MF MF MF MF MF MF MF MF MF Trigger Level Level Level Level Level Level Level Level Level Level Level Level Level Level Level Level TTL TTL TTL 24V TTL TTL TTL TTL TTL 0V TTL TTL High Level TTL TTL 24V 24V TTL TTL TTL TTL * Low Level TTL 0V 0V 0V TTL TTL TTL TTL * Analog Note
MAIN MOTOR
24VDC
P/J16
RTN /MOT REV (TTL) MOT ALM (TTL) /MAIN MOT(TTL)
1 2 3 4 5
hc2m801F
Pin numbers and voltage levels for the MCU Main Motor path
P16 3 4 5 Signal Name /MOT REV (TTL) MOT ALARM (TTL) /MAIN MOT (TTL) Signal Direction MCUMain Motor MCUMain Motor MCUMain Motor Trigger Level Level Level High Level Low Level TTL TTL TTL TTL TTL TTL
TONER SENSOR
P/J221
1 2 3 4
P/J 922
1 2 3 4
P/J 222
4 3 2 1
P/J22
1 2 3 4
hc2m802F
Pin numbers and voltage levels for the MCU Toner Sensor path
P22 4 P222 1 P922 4 P221 4 Signal Name /NO TONER (TTL) Signal Direction MCUToner Sensor Trigger Level High Level TTL Low Level TTL
MCU DUPLEX I/F PWB FUSER COVER SWITCH or MCU FUSER COVER SWITCH
J182 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 P/J 18
18 17 16 15 14 13 12
P/J 190
2 1
P/J 180
1 2
COVER SWITCH
MCU
OR
P/J190
2 1
18 17 16 15 14 13 SG 12 11 10 9
COVER SWITCH
8 7 6 5 4 3 2 1
hc2m803F
Signal names for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path
Signal Name /FCOVER OPEN (TTL) Description Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch is deactivated (the Fuser Cover is open).
Pin numbers and voltage level for the MCU DUPLEX I/F PWB FUSER COVER SWITCH path
P18 9 P180 1 P190 2 Signal Name /FCOVER OPEN (TTL) Signal Direction MCUFuser Cover Switch Trigger Level High Level TTL
Pin numbers and voltage level for the MCU FUSER COVER SWITCH path
P18 8 P190 1 Signal Name /FCOVER OPEN (TTL) Signal Direction MCUFuser Cover Switch Trigger Level High Level TTL
P/J421
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
hc2m804F
CONTROLLER
CONTROL PANEL
P412
To Controller
+5v
P421- 4 P421- 3 P421- 8 P421- 7 P421- 6 P421- 5 P421- 9 P421-10 P421-11 P421-12 P421-13 P421-14 P421-15 P421-16
E RS DB7 DB6 DB5 DB4 KEY8 KEY7 KEY6 KEY5 KEY4 KEY3 KEY2 KEY1
10K
P421- 2 P421- 1
+5v SG
+5V
0.1 + CER
47 ALM
Buffer
Online
SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8
Continue
Enter
*
+
Menu
Item
Value
150
150
150
150
LED1
LED2
LED3
LED4
Shift
Description Register selecting signal which selects the command registers or the data registers. Low: Command registers, High: Data registers
Pin numbers and voltage levels for the CONTROLLER CONTROL PANEL path
Signal Direction C: Controller P411 14 512 1316 17 18 P421 2017 169 85 4 3 Signal Name /LED4 (TTL) /LED1 (TTL) /KEY1 (TTL) /KEY8 (TTL) DB7(TTL) DB4 (TTL) E (TTL) RS (TTL) CP: Control Panel CCP CCP CCP CCP CCP Trigger Level Level Level Level Level High Level TTL TTL TTL TTL TTL
P/J31
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 /TPRINT /PRFD /CCLK /VDO +5V /CBSY /STA /TOP /PPRDY SG SG SG SG /CMD /CPRDY /START /PCLK /SBSY /RDY /BD
P411
CONTROLLER
P23
1 2 SG /TPRINT (TTL)
P/J412
P/J126
LVPS
1 2
5VDC SG
hc2m805F
Pin numbers and voltage levels for the Controller MCU path
P/J31 A1 Signal Name /TPRINT Signal Direction MCUController Trigger Level High Level TTL Low Level TTL
A3
/CCLK
MCUController
A2
/PRFD
MCUController
339
PIN B10
SIGNAL /BD
DIRECTION MCUController
DESCTIPTION Beam Detect: Horizontal synchronization signal. The Controller begins to send the video data for one scan line when it receives this signal. /BD is sent at the following time intervals. v 300 dpi: 930.4 ms/480 dpi: 581.5 ms v 360 dpi: 775.3 ms/600 dpi: 465.2 ms v 400 dpi: 697.8 ms/800 dpi: 348.9 ms Ready: The MCU holds this signal Low when it can accept /PRFD and /START. When /RDY is High, /PRFD and /START are ignored. The MCU raises /RDY High when the printer is in one of the following states: 1. Call 2. Pause/Diagnostic 3. Wait 4. Misprint 5. /PPRDY at High
B9
/RDY
MCUController
B8 B7 B6
Status Busy: The MCU holds this signal Low when it is sending a Status. Printer Clock: Clock signal that the MCU supplies and uses for synchronized transmission of a Status. START: Orders the printer to start the print operation. This signal is valid only when /RDY is Low.
340
PIN B5
SIGNAL /CPRDY
DIRECTION MCUController
DESCTIPTION Controller Power Ready: Goes Low when the Controller is powered on and completes initialization. When this signal goes High, the printer resets to the powered-on state. v Printer stateStandby (ROS: Off, Fuser: On) When the printer is in the Printing state or the Print Ready state, the printer returns to the Standby state immediately or after the print operation is completed. When in the Pause state (ROS: Off, Fuser: Off), the printer returns to the Standby state except when the Fan is stopped. (continued)
B5
/CPRDY
MCUController
v ResolutionHigher resolution When the printer has two resolutions and the lower resolution is selected, the resolution returns to the Higher resolution. v Paper size mismatch detectionEnabled v Fuser temperatureNormal temperature When the high temperature for thick paper is selected, the fuser temperature returns to the normal temperature.
B4
/CMD
MCUController
MCU Feeder PWB Feeder PWB Feeder PWB Feed Solenoid, No Paper Sensor, and Electromagnetic Clutch
2nd Tray (Optional)
FEEDER ASSY
ELECTROMAGNETIC CST NO PAPER CLUTCH AUX. SENSOR FEED SOLENOID
P/J 205 3 2 1
1 2 204 2 1 P/J
/ FEED 2 ON (L) 24VDC
P/J
/ NO PAPER 2 (TTL)
904
P.UP
SG
1st Tray
MCU PWB
P/J20
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11
P/J203 1 2 3 4 5 6 7 8 9
FEEDER PWB
P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
P/J207
A
P/J201
N.C. PSIZE2 (TTL) N.C. /FEED2 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) N.C. /NO PAPER2 (TTL) FEEDER CHECK SVDC 24VDC RTN SG OPTION /NO PAPER3 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL) N.C.
5VDC A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 24VDC
24VDC
24VDC
P207 P/J202
M
A10 A9 N.C. 1 2 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
P/J202
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
G H
24VDC
F
B E
A10 A9 A8 A7 A6
K Y I W J
A8 A7 A6 A5 A4 A3 A2 A1 B10 B9 B8
C D
A5 A4 A3 A2 A1 B10 B9 B8
B7 B6 B5 B4
J X Z K M
B7 B6 B5 B4
E F
B A
B3 B2 B1
H G
B3 B2 B1
Z Y X w
5VDC
5VDC
FEEDER PWB
hc2m816F
FEEDER ASSY
FEED SOLENOID
P/J 205 3 2 1
1 2 204 2 1 P/J
/ FEED 3 ON (L) 24VDC
P/J
/ NO PAPER 3 (TTL)
904
P.UP
SG
1st Tray
MCU PWB
P/J20
A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 B1 B2 B3 B4 B5 B6 B7 B8 B9 B10 B11
P/J203 1 2 3 4 5 6 7 8 9
FEEDER PWB
P/J201
A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1
P/J207
A
F B
P/J201
N.C. PSIZE2 (TTL) N.C. /FEED1 ON(L) 24VDC /SIZE 3BIT(TTL) /SIZE 1BIT(TTL) N.C. /NO PAPER1 (TTL) FEEDER CHECK SVDC 24VDC RTN SG OPTION /NO PAPER2 (TTL) OPTION /SIZE 2BIT(TTL) /SIZE 4BIT(TTL) /FEED2 ON(L) 24VDC TURN (TTL) PSIZE2 (TTL) N.C.
5VDC A11 A10 A9 A8 A7 A6 A5 A4 A3 A2 A1 B12 B11 B10 B9 B8 B7 B6 B5 B4 B3 B2 B1 24VDC
24VDC
24VDC
P207 P/J202
M
A10 A9 N.C. 1 2 3 4 5 6 N.C. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
A
F B
A1 A2 A3
P/J202
A10 A9
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
G H
24VDC
A4 A5 A6
A8 A7 A6
K Y I W J
A8 A7 A6 A5 A4 A3 A2 A1 B10 B9 B8
C D
A7 A8 A9 A10 A11 B1 B2 B3
C D
A5 A4 A3 A2 A1 B10 B9 B8
B4 B5 B6 B7
B7 B6 B5 B4
J X Z K M
B7 B6 B5 B4
B8 B9
B3 B2
H G
B3 B2 B1
B10 B11
B1
Z Y X w
5VDC
5VDC
FEEDER PWB
hc2m807F
/FEED2 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER2 (TTL) FEEDER CHECK /NO PAPER3 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL)
Pin numbers and voltage levels for the Feeder PWB (Feeder1) Feeder PWB (Feeder2) path
Signal Direction P202 (Feeder1) A10 A8 A7 A6 A4 A3 B7 B5 B4 B3 B2 B1 P201 (Feeder2) A10 A8 A7 A6 A4 A3 B9 B7 B6 B5 B4 B3 F1: Feeder1 Signal Name PSIZE2 (TTL) /FEED2 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER2 (TTL) FEEDER CHECK /NO PAPER3 (TTL) /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) PSIZE3 (TTL) F2: Feeder2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 F1F2 Trigger Level Level Level Level Level Level Level Level Level Level Level Level High Level TTL 24V TTL TTL TTL * TTL TTL TTL 24V TTL TTL Low Level TTL 0V TTL TTL TTL * TTL TTL TTL 0V TTL TTL Analog
Note
*: Refer to the description of the detection of the feeder conguration on the next page.
Pin numbers and voltage levels for the Feeder PWB (Feeder2) Feeder PWB (Feeder3) path
Signal Direction P202 (Feeder2) A10 A8 A7 A6 A4 A3 B5 B4 B3 B2 P201 (Feeder3) A10 A8 A7 A6 A4 A3 B7 B6 B5 B4 F2: Feeder2 Signal Name PSIZE3 (TTL) /FEED3 ON(L) 24VDC /SIZE 3BIT (TTL) /SIZE 1BIT (TTL) /NO PAPER3 (TTL) FEEDER CHECK /SIZE 2BIT (TTL) /SIZE 4BIT (TTL) /FEED3 ON(L) 24VDC TURN (TTL) F3: Feeder3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 F2F3 Trigger Level Level Level Level Level Level Level Level Level Level High Level TTL 24V TTL TTL TTL * TTL TTL 24V TTL Low Level TTL 0V TTL TTL TTL * TTL TTL 0V TTL Analog
Note
*: Refer to the description of the detection of the feeder conguration on the next page.
TRAY 1
MCU PWB
5VDC
TRAY 2
FEEDER PWB
TRAY 3
FEEDER PWB
FEEDER PWB
RF
RF
Detection Circuit
RM
SG
hc2m814F
Feeder Conguration Feeder1 (standard Feeder) not connected Feeder1 only One optional Feeder added Two optional Feeders added
Feeder 1
Feeder 2
Feeder 3
O O O O O O
MCU Duplex I/F PWB Duplex PWB and Fuser Cover Switch Duplex PWB Dup Stack Sensor, Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor
COVER SWITCH P/J192
1 2 3
P.UP
P/J184
5VDC 1 2 P/J190
1 2 3 4 5 6
SG / FULL (TTL)
P/J193
2 1
1 P/J180
P/J198
2 1
DUP B DUP / A DUP A DUP / B RTN SG 24VDC N.C. / DUP COVER (TTL) 5VDC / FULL (TTL) / OCT REV (TTL) / OCT ON (TTL) / DUP SNS (TTL)
P/J183
1 2 3 4 5 6 7 8 9 10 11 12 13 14
P/J187
1
P/J197
A B 24VDC 24VDC /A /B
1 2 3 4 5 6
2 3 4 5 6 7 8
M
P/J195
1 2
DUPLEX MOTOR
P/J186
1
P/J196
MOT + MOT 1 2
OFFSET MOTOR
5VDC 24VDC
1 2
3 4 5 6
7 8
9 10 11 12 13 14 15 16 17 18
P/J18
MCU PWB
Signal names for the Duplex I/F PWB Duplex PWB path
Signal Name DUP B DUP /A DUP A DUP /B /DUP COVER (TTL) Description Duplex Motor exciting signal. Duplex Motor exciting signal. Duplex Motor exciting signal. Duplex Motor exciting signal. Signal from the Dup Cover Switches 1 and 2. This signal is LOW when both the Dup Cover Switches 1 and 2 are closed and High when the Dup Cover Switch1 or the Dup Cover Switch2 is open. Signal through the Dup Stack Sensor. This signal is LOW when the Dup Stack Sensor is activated by the stack of delivered printed sheets higher than the predetermined height. This signal is also used to detect whether the Duplex Unit is installed when printer power is switched on. /OCT REV (TTL) Control signal to switch the direction of rotation of the Offset Motor between Normal and Reverse. LOW: Reverse direction, HIGH: Normal direction /OCT ON (TTL) /DUP SNS (TTL) Offset Motor Control Signal to switch the Offset Motor on and off. Signal from the Duplex Pass Sensor. This signal is LOW when the Duplex Pass Sensor is activated by the paper.
/FULL
Pin numbers and voltage levels for the Duplex I/F PWB Duplex PWB path
Signal Direction DIF: Dup I/F PWB P182 1 9 2 10 5 6 14 7 15 P183 1 2 3 4 9 11 12 13 14 Signal Name DUP B DUP /A DUP A DUP /B /DUP COVER (TTL) /FULL /OCT REV (TTL) /OCT ON (TTL) /DUP SNS (TTL) D: Duplex PWB DIFD DIFD DIFD DIFD DIFD DIFD DIFD DIFD DIFD Trigger Level Level Level Level Level Level Level Level Level TTL * TTL TTL TTL TTL 0V TTL TTL TTL High Level
Low Level
* Refer to the description of the Duplex unit detection on the next page.
Pin numbers and voltage levels for the Duplex PWB Offset Motor path
Signal Direction D: Duplex PWB P186 1 2 P196 1 2 Signal Name MOT+ MOTOM: Offset Motor D OM D OM Trigger Level Level High Level 24 VDC 24 VDC Low Level 0V 0V
CPU
P/J:M1 (+) (-) P/J:S2 1 3 P/J:S1 1 3 P/J:S3 1 3 P/J:S7 2 1 P/J:S11 1 3 P/J:P1 3 2 1 5 4 P/J:P2 1 2 3 P/J:S10 1 2 3 P/J:S6 1 2 P/J:S8 1 2 3 P/J:M2 1 2 3 4 P/J:S9 1 2 P/J:S12 1 2
SIZE SENSOR
DC21 SWHU1 SWHU1 SWHU2 +5VDC LSPE(TTL) SG DC11 DC12 +5VDC ENCOD(TTL) SG +5VDC LSPL(TTL) SG SWCPR(TTL) SG +5VDC LSPEX(TTL) SG SM1 SM2 SM3 SM4 SWDO1(TTL) SG SWDO1(TTL) SWDO(TTL)
NO PAPER SENSOR
FEED MOTOR
ENCODER
SG
SENSOR
TRANSPORT MOTOR
LEFT HAND COVER OPEN SWITCH RIGHT HAND COVER OPEN SWITCH
AC to DC
SERVICE CONNECT
AC INLET
hc2m089F
This is an internal wiring of the FEED ROLLER KIT, therefore the P/J No. and Pin No. are omitted.
Description LIGHT SENSOR PAPER EXIT This signal indicates that a paper is in the transport.
SM1
SM2
SM3
SM4
SWITCH DOOR OPEN This signal indicates an open rear cover. SWITCH HAZARD UP This safety switch interrupts the motor current if the Paper Level Sensor does not work and the elevator moves up too much. SWITCH PAPER SIZE This signal displays the used paper size in the HCF.
Pin numbers and voltage levels for the HCF LVPS Components
P: XS1-1 XS1-2 XS1-3 XS1-4 XS1-5 XS1-6 XS1-7 XS1-8 XS1-9 XS1-10 XS2-1 XS2-2 XS2-3 XS2-4 XS2-5 XS2-6 XS2-7 XS2-8 XS2-9 P1-5 P1-4 P1-3 P1-2 P1-1 P2-1 P2-2 P2-3 S6-1 P: M1-(+) M1-(-) S1-1 S1-3 S2-1 S2-3 S3-1 S3-3 Signal Name DC21 DC22 SG SWPL (TTL) DC22 SWHD SG SWPSZ (TTL) SG SG DC11 DC12 +5V LSPE (TTL) SG +5V ENCOD (TTL) SG SWCPR (TTL) Signal Direction Floating Signal (see note 1) Floating Signal (see note 1) Power Near Empty Sensor LVPS Floating Signal (see note 1) Floating Signal (see note 1) Power Paper Size Sensor LVPS Power Power LVPS Feed Motor LVPS Feed Motor Power No Paper Sensor LVPS Power Power Encoder LVPS Power Tray Set Sensor 1 LVPS Trigger LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL LEVEL High Level 0V 24V 0V TTL 24V 24V 0V TTL 0V 0V 24V 24V 5V TTL 0V 5V TTL 0V TTL TTL TTL TTL 0V (see note 2) 0V (see note 2) TTL TTL 0V 0V Low Level 24V 0V
Signal Direction Power Floating Signal (see note 1) Floating Signal (see note 1) Power Sensor LVPS Power Left Hand Cover Open Switch Right Hand Cover Open Switch Power LVPS Transport Motor LVPS Transport Motor LVPS Transport Motor LVPS Transport Motor Power Paper Level Sensor LVPS Power Floating Signal (see note 1) Floating Signal (see note 1)
Low Level
0V 0V
TTL
TTL
XS2-17 XS2-18 XS2-19 XS2-20 XS2-21 XS2-22 XS2-23 XS2-24 XS2-25 XS2-26
S9-2 M2-1 M2-2 M2-3 M2-4 S10-1 S10-2 S10-3 S11-1 S11-3
0V 24V 24V 24V 24V 5V TTL 0V 24V 24V 0V 0V TTL 0V (see note 3) 0V (see note 3) 0V (see note 3) 0V (see note 3)
P: XS2-27
P: S12-1
Signal Direction Left Hand Cover Open Switch Right Hand Cover Open Switch Right Hand Cover Open Switch LVPS
Trigger LEVEL
XS2-28
S12-2
SWDO
LEVEL
TTL
TTL
Notes: 1. This signal is used to stop the Elevator Motor when it is not responding. It is connected to the Drive Power cable and the Serial port (no direction). 2. PWM (Pulse Width Modulation) Signal 3. Rectangle Signal
Chapter 5. Locations
Quick Path . . . . . . . . . . . . . Covers and Assemblies . . . . . . Electrical Components . . . . . . . Clutches, Solenoids, Motors, and Connectors . . . . . . . . . . . Printed Wiring Boards (PWBs). . Sensors . . . . . . . . . . . . . Switches . . . . . . . . . . . . . Mechanical and Miscellaneous . . . . . . . . . . . Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361 .362 .364 .364 .367 .380 .384 .386 .390
360
Quick Path
To... Assemblies Clutches Connectors Covers Fans Mechanical Motors Paper Path Printed Wiring Boards (PWBs) / Power Supplies Sensors Solenoids Switches Location Tables with Links to Illustrations, to the Parts Catalog, to Wiring and Pinout Diagrams, and to Removals Table 59 on page 362 Table 60 on page 364 Table 61 on page 367 Table 59 on page 362 Table 60 on page 364 Table 65 on page 390 Table 60 on page 364 Figure 23 on page 392 Table 62 on page 380 Table 63 on page 384 Table 60 on page 364 Table 64 on page 386
Operator panel
Top cover
Fuser cover
Side cover
Power switch
Auxiliary tray
Duplex covers
CL2 Tray 2/3 Electromagnetic (Turn) Fig. 7, p. 366 / 7 Clutch SL1 Tray 2/3 Feed Solenoid Fig. 7, p. 366 / 8 Fig. 8, p. 366/ 9 Fig. 8, p. 366/ 10 Fig. 9, p. 367/ 11 Fig. 9, p. 367/ 12 Fig. 9, p. 367/ 13
Duplex
HCF
Chapter 5. Locations
364
2 3 6 5 4
hc2m222F
HC2M122F
10
HC2M118F
12 11 13
hc2m130F
Connectors
Table 61. Connectors, Printer
Connector P/J 11 12 13 14 15 16 Figure / Grid Fig. 11, p. 375 / C4 Fig. 11, p. 375 / B3 Fig. 11, p. 375/ B4 Fig. 11, p. 375 / B3 Fig. 11, p. 375 / B4 Fig. 11, p. 375 / B3 From... MCU PWB... LVPS Assembly MCU PWB... ROS Assembly MCU PWB... High Harness Assembly (Registration Clutch, Registration Sensor, No Paper Sensor, and Feed Solenoid) MCU PWB... High Harness Assembly (Full Stuck Sensor, Temperature Sensor, and Exit Sensor) MCU PWB... HVPS Assembly MCU PWB... Main Motor To... Wiring Diagram p. 311 p. 315 p. 322 p. 313 p. 319 p. 329 Pinout Diagram p. 311 p. 317 p. 324 p. 314 p. 321 p. 330 Chapter 5. Locations 367
MCU PWB... diagnostic tool console panel (open connector) p. 310 MCU PWB... Feeder PWB MCU PWB... Interlock Switch MCU PWB... Toner Sensor Open connector for producing test print output (two pins) MCU PWB... ESS PWB ROS Assembly (LD Assembly)... MCU PWB ROS Assembly (SOS PWB)... MCU PWB ROS Assembly (Scanner Assembly)... MCU PWB LVPS Assembly... LMCU PWB LVPS Assembly... Fan LVPS Assembly... Interlock Switch LVPS Assembly... High Harness Assembly Heater Rod LVPS Assembly... ESS Open connector (plug) on LVPS Assembly board p. 325 p. 311 p. 331 p. 310 p. 337 p. 315 p. 315 p. 315 p. 311 p. 311 p. 311 p. 311 p. 337 p. 311
Chapter 5. Locations
368
Registration Clutch Assembly... High Harness Assembly (MCU PWB) Registration Sensor... High Harness Assembly (MCU PWB) MSI No Paper Sensor... MCU PWB Feed Solenoid... High Harness Assembly (MCU PWB) MSI Bracket Assembly (MSI N/P Harness)... High Harness Assembly (MCU PWB) Fuser Assembly (Heater Assembly)... Transport Chute Assembly (High Harness Assembly (MCU PWB) Temperature Sensor Assembly... Fuser Harness (MCU PWB) Exit Sensor... MCU PWB Full Stuck Sensor... MCU PWB HVPS Assembly... MCU PWB CRU Sensor Assembly internals... MCU PWB Duplex Interface PWB... Fuser Cover Switch Duplex Interface PWB... Duplex Unit (Duplex Cable) Duplex Cable... Duplex PWB Duplex Sensor Harness... Duplex PWB Offset Motor... Duplex PWB
Chapter 5. Locations
369
Duplex Motor Harness... Duplex PWB Fuser Cover Switch... Duplex Interface PWB Duplex Sensor Harness... Duplex Stack Sensor Duplex Sensor Harness... Duplex Cover Switch 1 Duplex Motor Harness... Duplex Pass Sensor Offset Motor Duplex Motor Harness... Duplex Motor Duplex Sensor Harness... Duplex Cover Switch 1 Feeder PWB... MCU PWB Feeder PWB... Tray Lower1 Harness Feeder PWB... Feeder Harness (Turn Clutch, No Paper Sensor, and Feed Solenoid) Feed Solenoid... MCU PWB Cassette No Paper Sensor... MCU PWB Electromagnetic Clutch... MCU PWB
Chapter 5. Locations
370
Tray Lower1 Harness... options Feeder Assembly (Plugs) Toner Sensor... MCU PWB MSI Bracket Assembly (Toner Sensor Harness)... Toner Relay Harness (MCU PWB) Console Assembly... Controller Feed Solenoid... MCU PWB MCU PWB ... Electromagnetic Clutch Toner Sensor... MCU PWB Feed Solenoid... MCU PWB MSI No Paper Sensor... MCU PWB Fuser Harness... Heater Assembly Fuser Harness internal connector
HVPS Assembly... CRU Guide Assembly Left (Power supply p. 319 for BCR) HVPS Assembly... CRU Guide Assembly Left (Power supply p. 319 for magnet roll) HVPS Assembly... High Harness Assembly (Power supply for Detack Saw) Harness... Lift Up Motor p. 319 p. 353
Chapter 5. Locations
371
Chapter 5. Locations
372
J142, J942
J421
J132
J134
HC2M111F
J180 J113
A
J171
CR
J151 TR J12
B
J31
J22 J13
J20
J127 J131
C
J122
HC2M112F
J201 J202
J207
P207
B B
J203
hc2m126F
J197
J196
P182
J198
hc2m117F
P2
S6
S7
M2 S3 S1 M1 S2 S9
C
S8
hc2m128F
1 3
2 4
HC2M116F
7 6 5
HC2M125F
HC2M121F
10
hc2m129F
Sensors
Table 63. Sensors
Unit CRU sensor Full stack sensor Exit sensor Printer Temperature sensor Registration sensor Auxiliary tray no-paper sensor Toner sensor Cassette no-paper sensor Duplex Feeder Duplex stack sensor Duplex pass sensor Sensor Figure / Reference Fig. 19, p. 387 / 1 Fig. 19, p. 387/ 2 Fig. 19, p. 387/ 3 Fig. 19, p. 387/ 4 Fig. 19, p. 387/ 5 Fig. 19, p. 387/ 6 Fig. 19, p. 387/ 7 Fig. 19, p. 387/ 10 Fig. 21, p. 388 / 14 Fig. 21, p. 388/ 13 Parts Catalog Asm. Index 1115, p. 572 87, p. 564 825, p. 564 99, p. 567 76, p. 562 59, p. 557 513, p. 557 311, p. 553 3017, p. 652 3013, p. 652 2021, p. 697 Wiring Diagram (Grid) p. 315 p. 313 p. 313 p. 313 p. 322 p. 322 p. 331 p. 342 p. 349 p. 349 p. 342 Pinout Diagram (Grid) p. 317 p. 314 p. 314 p. 314 p. 324 p. 324 p. 331 p. 342 p. 349 p. 349 p. 342 Removal p. 503 p. 487 p. 487 p. 487 p. 484 p. 460 p. 462 p. 430 p. 635 p. 633 p. 683
Switches
Table 64. Switches
Unit Switch Interlock switch Fuser cover switch Duplex cover switch 1 Duplex cover switch 2 Paper size switch (on feeder PWB) Right hand cover open switch Left hand cover open switch Figure / Reference Fig. 19, p. 387 / 8 Fig. 19, p. 387/ 9 Fig. 21, p. 388 / 15 Fig. 21, p. 388/ 16 Fig. 20, p. 388 / 11 Fig. 22, p. 389 / 24 Fig. 22, p. 389 / 26 Parts Catalog Asm. Index 121, p. 575 122, p. 575 3011, p. 652 3012, p. 652 2011, p. 697 429, p. 778 4220, p. 778 Wiring Diagram (Grid) p. 311 p. 332 p. 349 p. 349 p. 342 p. 353 p. 353 Pinout Diagram (Grid) p. 311 p. 332 p. 349 p. 349 p. 342 p. 353 p. 353 Removal p. 513 p. 516 p. 629 p. 631 p. 674 p. 743 p. 758
Printer
2 3 4
5 7 6
hc2m223F
10
11
hc2m224F
12
13 14
15
16
hc2m225F
22 23 24
21
20
hc2m127F
17
18
19
25
27 26
Chapter 5. Locations
390
Chapter 5. Locations
391
7 6 5 4 3
8 9 10 11 12
13 14
1 15
FRONT
16 17 18 19 20 21 22 23
24 25 26 27
hc2m785F
28
29
30 31
hc2m226F
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.400 .401 .401 .402 .402 .403 .404 .404 .405 .406 .406 .407 .408 .408 .409 .410 .410 .411 .412 .413 .413 .414 .414 .415 .416 .416 .417 394
Console Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Feeder PWB . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Turn In Chute . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Turn Chute Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette Guide Assembly Left. . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette No Paper Sensor . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette Guide Assembly Right . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Cassette No Paper Actuator . . . . . . Removal . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . Feed Roll . . . . . . . . . . . . . . . You may follow either procedure A or Procedure A Removal . . . . . . . . Replacement. . . . . . . . . . . . . Procedure B Removal . . . . . . . . Replacement. . . . . . . . . . . . .
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.418 .419 .419 .420 .420 .421 .422 .423 .423 .424 .425 .425 .426 .426 .428 .430 .430 .431 .433 .433 .435 .436 .436 .437 .438 .438 .439 .439 .439 .440
Feed Shaft Assembly . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Feed Solenoid . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Electromagnetic Clutch . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Turn Roll Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Rear Roll Assembly . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Front Tray Assembly and Front in Tray . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Auxiliary Tray Bracket Assembly . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Auxiliary Tray No Paper Sensor/Actuator Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Toner Sensor Assembly . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . . Front Bottom Tray . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . Replacement. . . . . . . . . . . . . .
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.442 .442 .444 .446 .446 .448 .449 .449 .450 .451 .451 .452 .453 .453 .454 .455 .455 .456 .457 .457 .458 .460 .460 .461 .462 .462 .463 .464 .464 .465
BTR Assembly . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Chute Assembly. . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Pick Up Roll . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Pick Up Solenoid . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Retard Pad Assembly . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Registration Sensor/Actuator . Removal . . . . . . . . . . . Replacement. . . . . . . . . Fuser Assembly . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Main Motor. . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Handling Gear Assembly Removal . . . . . . . . . . . Replacement. . . . . . . . . Registration Clutch Assembly . Removal . . . . . . . . . . . Replacement. . . . . . . . .
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.466 .467 .467 .468 .468 .471 .474 .474 .475 .477 .477 .478 .480 .481 .482 .484 .484 .486 .487 .488 .488 .489 .490 .490 .492 .493 .494 .495 .495 .496
Main Gear Assembly. . . . Removal . . . . . . . . . Replacement. . . . . . . Pop Up Unit . . . . . . . . Removal . . . . . . . . . Replacement. . . . . . . CRU Sensor Assembly . . Removal . . . . . . . . . Replacement. . . . . . . CRU Guide Assembly Left . Removal . . . . . . . . . Replacement. . . . . . . CRU Guide Assembly Right Removal . . . . . . . . . Replacement. . . . . . . Interlock Switch . . . . . . Removal . . . . . . . . . Replacement. . . . . . . Fuser Cover Switch . . . . Removal . . . . . . . . . Replacement. . . . . . . Fan . . . . . . . . . . . . Removal . . . . . . . . . Replacement. . . . . . . LVPS Assembly . . . . . . Removal . . . . . . . . . Replacement. . . . . . . Duplex Interface PWB . . . Removal . . . . . . . . . Replacement. . . . . . .
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.497 .497 .499 .500 .501 .502 .503 .504 .505 .506 .507 .508 .510 .510 .511 .513 .513 .515 .516 .516 .517 .518 .519 .519 .521 .522 .523 .524 .525 .525
MCU PWB without MCU Holder . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . MCU PWB with MCU Holder . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . HVPS . . . . . . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller Assembly . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller PWB . . . . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Controller PWB SIMM . . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . . Network Interface Card . . . . . Removal . . . . . . . . . . . . Replacement. . . . . . . . . .
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.526 .527 .527 .529 .530 .531 .532 .532 .533 .535 .535 .536 .537 .537 .538 .539 .539 .540 .541 .541 .542
hc2m957f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove duplex unit (See page 615), if supplied. 3. Open the fuser cap cover (1) (Asm-Index: 1-3, page 548). 4. Lift up the fuser cap cover and remove from the fuser cover (2) (Asm-Index: 1-2, page 548). 5. Open the fuser cover and hold the cover midway (approximately 30 degrees). 6. Use you right hand to hold the left end of the fuser cover, and press its center from the inside. Use your left hand to unhook the right side hinge pin (5) from the hinge hole on the rear tie plate (6) (Asm-Index: 10-5, page 570). 7. Release the left side hinge pin (3) of the fuser cover from the hinge hole on the rear tie plate (6).
Replacement
Reverse the Removal procedure.
1 2
J131
hc2m958F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).
Chapter 6. Removal Procedures, Adjustments 402
3. Open the front tray assembly (Asm-Index: 5-1, page 557). 4. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572). 5. Remove the two screws (2) securing the left top cover to the printer frame. 6. Lift up the back of the left top cover. 7. Release the hook (3) from the front side cover (Asm-Index: 1-11, page 548) and remove the left top cover from the printer body. Attention: Support the left top cover to prevent damage to the console earth wire and the console harness. 8. Turn the left top cover to the left. 9. Disconnect CN1 of the console harness (Asm-Index: 13-8, page 578) at the back of the console assembly (Asm-Index: 1-18, page 548).
Replacement
Reverse the Removal procedure.
2 2
hc2m413f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 404
3. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572) 4. Remove the two screws (2) securing the right top cover. 5. Lift the cover away from the printer frame.
Replacement
Reverse the Removal procedure.
FRONT
4 3 5 8 7 1 8
6 7 1 2 6
hc2m972f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Loosen the two knurled screws (1) securing the left cover assembly (2).
Chapter 6. Removal Procedures, Adjustments 406
3. Slide the cover backwards to remove its front edge from the front side cover (3) (Asm-Index: 1-11, page 548), and remove the cover from the printer frame.
Replacement
1. Insert the top edge of the cover (4) into the top slot (5). 2. Line the three hooks (6) up with the three openings (7) in the printer frame. 3. Slide the cover toward the front of the printer until the front tabs (8) t into the grooves on the front side cover (3). Attention: Ensure that the top edge of the cover ts inside the lower edge of the left top cover. 4. Secure the left cover assembly using two knurled screws.
2 1
hc2m415f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left cover assembly (See page 406). 3. Remove the two screws (1) securing the left lower cover (2). 4. Remove the cover from the printer frame.
Replacement
Reverse the Removal procedure.
1 3
hc2m416f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
3. Remove the right top cover (See page 404). 4. Remove the two screws (1) securing the bottom of the right cover assembly (2). 5. Remove the three screws (3) securing the top and back of the cover. 6. Remove the cover.
Replacement
Reverse the Removal procedure.
1 1
hc2m417f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Push down on the two hooks (1) at the upper end of the front side cover and move the top of the cover away from the printer frame. 6. Lift up the cover slightly to clear the two hooks (2) at the bottom of the cover and remove the cover from the printer frame.
Replacement
1. Hold the front side cover slightly tilting the upper side toward the front, and insert the hooks (2) on the bottom end of the cover into the opening in the printer frame. 2. Push down on the two hooks (1) at the upper end of the cover and insert them into the openings of the printer frame. 3. Replace the left cover assembly (See page 406). 4. Replace the left top cover (See page 402). 5. Close the fuser cover assembly (Asm-Index: 1-1, page 548).
Exit Cover
Asm-Index: 1-12, page 548.
1 1
hc2m418f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). Note: Removing the fuser allows cables/wires to be re-routed on the cover wire retainer during replacement. 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Close the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572).
Chapter 6. Removal Procedures, Adjustments 414
6. Remove the two screws (1) securing the exit cover (2). 7. Tilt the exit cover toward the front so that the full stack actuator (3) (Asm-Index: 8-8, page 564) does not touch the cover. 8. Lift the cover and remove it from the printer frame.
Replacement
1. 2. 3. 4. 5. Lift the full stack actuator and hold it out of the way so that it will not touch the exit cover during step 2. Place the cover onto the printer frame. Secure the cover using two screws (silver, collared, 10mm). Open the Pop up/ROS assembly. Replace the right top cover (See page 404).
6. Replace the left top cover (See page 402). 7. Replace the fuser cover assembly (See page 402).
1 3
hc2m419f
Removal
See Figure 33. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 416
3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the exit cover (See page 414). 6. Open the Pop up/ROS assembly (1) (Asm-Index: 11-111-23, page 572). 7. Remove the two screws (2) securing the pop up cover assembly. 8. Close the Pop up/ROS assembly. 9. Slide the pop up cover assembly slightly toward the front of the printer to disengage the hooks (3) at the front and back of the cover. 10. Lift the cover assembly and remove the cover from the pop up frame (Asm-Index: 11-1, page 572).
Replacement
Reverse the Removal procedure.
Console Assembly
Asm-Index: 1-18, page 548.
CN1
JCN1
J131
hc2m41af
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (Asm-Index: 1-1, page 548). 3. Remove the left top cover (See page 402) and the console assembly (2)(Asm-Index: 1-18, page 548). 4. Turn the left top cover (1) upside down. 5. Release the tab at the bottom of the console assembly.
Replacement
Reverse the Removal procedure.
Feeder PWB
Asm-Index: 3-1, page 553.
2
J201 J202 FRONT
3
J203
hc2m973f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Remove the left top cover (See page 402). 4. Remove the left side cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 420
5. Remove the left lower cover (See page 408). 6. Remove the front side cover (See page 412). 7. Remove the controller (See page 535). 8. Remove the four screws (3) securing the feeder PWB (4). Note: To loosen the bottom left screw, insert the screwdriver through the opening in the printer frame. 9. Remove the tray lower 1 harness (1) (Asm-Index: 3-2, page 553) from the harness clamp (2). 10. Remove the feeder PWB from the printer frame. 11. Disconnect J201 of the tray harness (Asm-Index: 12-17, page 575), J202 of the tray lower 1 harness and J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB.
Replacement
Reverse the Removal procedure.
Turn In Chute
Asm-Index: 3-4, page 553.
FRONT
3 1
hc2m974F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Hold open the turn chute assembly (Asm-Index: 3-5, page 553). 4. Flex the left side arm (1) of the turn in chute and remove its hinge hole from the pin (2) on the cassette guide assembly left (Asm-Index: 3-6, page 553). 5. Remove the turn in chute (3) from the cassette guide (4).
Replacement
Reverse the Removal procedure.
2 1 2
hc2m433F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the turn in chute (See page 422). 3. 4. 5. 6. 7. 8. Hold the turn chute assembly (1) half open. Unhook the stoppers from the cassette guide left and right. Hold the chute assembly open and slide it to the left. Lift the rear of the printer and pull down the right side of the chute. Slide the chute to the right and remove it from the printer. Lower the printer.
Replacement
Reverse the Removal procedure.
4 5
J203
1 3
J206 J204
3
hc2m434f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 426
3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the turn in chute (See page 422). 7. Remove the turn chute assembly (See page 424). 8. Remove the controller assembly (See page 535). 9. Remove the LVPS assembly (See page 521). 10. Disconnect v J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB (Asm-Index: 3-1, page 553), v J204 from the feed solenoid (Asm-Index: 4-8, page 555), and v J206 of the feeder harness from the electromagnetic clutch (Asm-Index: 4-9, page 555). 11. Release the electromagnetic clutch side of the feeder harness from the clamp. 12. Remove the four screws (1) securing the cassette guide assembly left from outside of the frame.
13. Using a at blade screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in, one by one, to release them from the printer frame. 14. Tilt the cassette guide (4), pulling its bottom edge from the inside of the printer frame (5). 15. Ensure that the three upper hooks of the cassette guide are released from the printer frame.
16. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator (Asm-Index: 3-16, page 553). 17. Push all harnesses on the cassette guide to free them from the printer frame. 18. Remove the cassette guide from the printer frame.
Replacement
1. Hold the cassette guide assembly left with the bottom to the right and the top to the left so that it will not interfere with the cassette no paper actuator. 2. Insert the cassette guide into the paper cassette well. 3. Insert all connectors on the cassette guide through their openings in the printer frame. 4. Place the upper three hooks of the cassette guide in their holes in the printer frame. 5. Pull the harnesses to keep them from being pinched between the cassette guide and the printer frame. Note: Adjust the position of cassette guide by sliding it to the front or rear so that the positioning pins on the cassette guide enter into the openings in the printer frame. Press on the bottom of the cassette guide to tilt it up until the upper and lower hooks lock into position. Secure the cassette guide from the outside of the printer frame using the four screws (1). Reconnect: v J203 to the feeder PWB, v J204 to the feed solenoid, and v J206 to the electromagnetic clutch. Insert the electromagnetic clutch harness into the harness clamp. Replace the LVPS assembly (See page 521).
6. 7. 8.
9. 10.
11. Replace the controller assembly (See page 535). 12. Replace the turn chute assembly (See page 424). 13. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 428
14. Replace the front side cover (See page 412). 15. Replace the left cover assembly (See page 406). 16. Replace the left top cover (See page 402). 17. Replace the fuser cover assembly (See page 400).
J205
hc2m435f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550). 3. Open the fuser cover assembly (See page 400). 4. Remove the left top cover (See page 402).
5. Remove the left cover assembly (See page 406). 6. Remove the front side cover (See page 412). 7. Remove the controller assembly (See page 535). 8. Remove the turn in chute (See page 422). 9. Swing the arm of the cassette no paper actuator (1) (Asm-Index: 3-16, page 553) to the rear direction so that the actuator is away from the cassette no paper sensor (2). 10. Open the turn chute assembly (Asm-Index: 3-5, page 553). 11. Using a small screwdriver, release the hooks (3) of the cassette no paper sensor from the cassette guide assembly left (Asm-Index: 11-30, page 572). Attention: Do not move the cassette no paper sensor away. It is connected with the feeder harness. 12. Disconnect J205 from the sensor. 13. Remove the sensor.
Replacement
1. Swing up the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette no paper sensor. 2. Reconnect J205 to the cassette no paper sensor. 3. Position the sensor in the opening of the cassette guide, and press the sensor into place until it snaps into position. 4. Put the extra length of the harness into the wiring channel of the cassette guide so that the harness does not interfere with the gears. 5. Replace the turn in chute (See page 422) and close the turn chute assembly. 6. Replace the controller assembly (See page 535). 7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 431
8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400). 11. Replace the paper cassette.
3 1 3
hc2m436f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the right top cover (See page 404). 4. Remove the right cover assembly (See page 410).
5. 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.
Replacement
1. Hold the cassette guide assembly right with the lower side to the left and the upper side to the right. 2. Insert the cassette guide into the paper cassette well. 3. Position the upper three hooks of the cassette guide in their respective holes. Note: Adjust the position of the cassette guide by sliding it to the front or rear so that the positioning pins on the cassette guide enter into the openings in the printer frame. 4. Press the lower side of the cassette guide tilting it up until the upper and lower hooks are in position and the lower hooks snap into place. 5. Secure the cassette guide using three screws (gold, self tapping, 8mm). 6. Replace the turn chute assembly (See page 424). 7. Replace the turn in chute (See page 422). 8. Replace the front tray assembly (See page 455). 9. Replace the right cover assembly (See page 410). 10. Replace the right top cover (See page 404). 11. Replace the fuser cover assembly (See page 400).
hc2m437f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the left lower cover (See page 408).
Chapter 6. Removal Procedures, Adjustments 436
6. Remove the front side cover (See page 412). 7. Remove the front tray assembly (See page 455). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the LVPS assembly (See page 521). 12. Remove the cassette guide assembly left (See page 426). 13. Slide the shaft of the cassette no paper actuator (1) to the right (2). 14. Release the left end of the actuator from the hole. 15. Slide the actuator to the left and remove it from the printer frame.
Replacement
Reverse the Removal procedure.
Feed Roll
Asm-Index: 4-1, page 555.
2 1
hc2m441f
Procedure A Removal
1. Install the paper cassette (Asm: 2, page 550) (with paper). 2. Open the turn chute assembly (Asm-Index: 3-5, page 553) and watch the paper path. 3. Run a test print and switch off the main switch when the front end of the paper touches the turn roll assembly (Asm-Index: 4-10, page 555). 4. Remove the paper cassette. 5. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper actuator (Asm-Index: 3-16, page 553) with your rst, second and third ngers. 6. Press on the hook of the feed roll (1) to the front using your thumb to remove it.
Replacement
1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly. Note: Ensure that the cams are located between the left and right pairs of the feed roll. 3. Switch on the main power. 4. Replace the paper cassette.
Procedure B Removal
1. Remove the fuser cover assembly (See page 400). 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 439
6. Remove the turn chute assembly (See page 424). 7. Remove the controller assembly (See page 535). 8. Press down on the armature of the feed solenoid (2) (Asm-Index: 4-8, page 555) to engage the feed gear (3) (Asm-Index: 4-5, page 555) with the feed idler gear (4) (Asm-Index: 4-15, page 555). 9. Rotate the rotor (5) of the main motor (Asm-Index: 10-6, page 570) clockwise until the rubber surface of the feed roll faces to the front. Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls. 10. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper actuator, with your rst, second and third ngers. 11. Press on the hook of the feed roll to the front using your thumb to remove it.
Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly. Note: Ensure that the cams are located between the left and right pairs of the feed roll. 3. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of the feed roll (Asm-Index: 4-1, page 555) up until the feed gear (Asm-Index: 4-5, page 555) is released from the feed idler gear (Asm-Index: 4-15, page 555). 4. Replace the controller assembly (See page 535). 5. Replace the turn chute assembly (See page 424). 6. Replace the turn in chute (See page 422). 7. Replace the front side cover (See page 412).
Chapter 6. Removal Procedures, Adjustments 440
8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400).
1 4 6 7 3
5
hc2m442f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the four feed rolls (See page 438). 12. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555) and the feed solenoid (3) (Asm-Index: 4-8, page 555). 13. Remove the E-ring (4) that secures the feed gear to the feed shaft assembly (5). 14. Hold down the armature of the feed solenoid and remove the feed gear together with the feed core (Asm-Index: 4-3, page 555) and the feed core spring (Asm-Index: 4-4, page 555). 15. Remove the E-ring (6) that secures the right end the feed shaft assembly and remove the right side feed bearing (7) (Asm-Index: 4-6, page 555). 16. Slide the feed shaft to the left and remove the E-ring (8) that secures its left end. Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls. 17. Position the cassette no paper actuator at the lower position. 18. Slide the feed shaft to the right until its left end clears the printer frame. 19. Pull the feed shaft to the lower left and release its right end from the printer frame, and remove the shaft from the printer.
Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Position the cassette no paper actuator in the lower position. 2. Hold the feed shaft assembly with the at side to the left. 3. Hold the feed shaft, left end lowered and insert its right end into the right opening in the printer frame. 4. Slide the feed shaft to the right and insert its left end to the feed bearing. 5. Slide the feed shaft to the left and install an E-ring in the second groove from the left end. You may pull out the right end of the shaft to ease the installation of the E-ring. 6. Pressing the left end of the feed shaft to the right, insert the right side feed bearing into its opening in the printer frame. 7. Reinstall an E-ring to secure the right end of the feed shaft. 8. Rotate the shaft and position the at side up. 9. Holding down the armature of the feed solenoid, install the feed gear together with the feed core and the feed core spring. 10. Secure the feed gear to the feed shaft using an E-ring. 11. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) to the position that the larger holes on the feed shaft can be seen from the back of the printer body. 12. Replace the four feed rolls (See page 438). 13. Reinstall the feed spring between the feed gear and the feed solenoid. 14. Rotate the rotor of the main motor clockwise to place the rubber surface of the feed roll up until the feed gear is released from the feed idler gear (Asm-Index: 4-15, page 555). 15. Replace the controller assembly (See page 535). 16. Replace the turn chute assembly (See page 424). 17. Replace the turn in chute (See page 422).
Chapter 6. Removal Procedures, Adjustments 444
18. Replace the front side cover (See page 412). 19. Replace the right cover assembly (See page 410). 20. Replace the left cover assembly (See page 406). 21. Replace the right top cover (See page 404). 22. Replace the left top cover (See page 402). 23. Replace the fuser cover assembly (See page 400).
Feed Solenoid
Asm-Index: 4-8, page 555.
1 4
3
J204
hc2m443f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555) and the feed solenoid (3). 8. Disconnect J204 of the feed solenoid (4) from the feeder harness (Asm-Index: 3-12, page 553) on the cassette guide assembly left (Asm-Index: 3-6, page 553). 9. Remove the screw (5) securing the feed solenoid to the cassette guide and remove the solenoid.
Replacement
1. Place the feed solenoid in position and secure it using a screw (silver, 6mm). 2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly left. Attention: Route the harness so that it does not touch the gears. 3. Reinstall the feed spring between the feed gear and the feed solenoid. 4. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of the feed roll (Asm-Index: 4-1, page 555) up until the feed gear is released from the feed idler gear (Asm-Index: 4-15, page 555). 5. Press the armature of the feed solenoid and ensure the feed gear is released from the armature. 6. Turn the feed gear clockwise and ensure the armature of the feed solenoid holds the feed gear. 7. Replace the controller assembly (See page 535). 8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402). 11. Replace the fuser cover assembly (See page 400).
Electromagnetic Clutch
Asm-Index: 4-9, page 555.
1 2
J206
hc2m444f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535).
Chapter 6. Removal Procedures, Adjustments 449
7. Disconnect J206 from the electromagnetic clutch (1). 8. Remove the E-ring (2) securing the clutch. 9. Remove the clutch from the turn roll assembly (Asm-Index: 4-10, page 555).
Replacement
1. Place the electromagnetic clutch on the turn roll assembly and insert the notch on the clutch to the arm over the printer frame. 2. Secure the clutch using an E-ring. 3. Reconnect P/J206 to the clutch. Attention: Route the harness so that it does not touch the gears. 4. Replace the controller assembly (See page 535). 5. Replace the front side cover (See page 412). 6. Replace the left cover assembly (See page 406). 7. Replace the left top cover (See page 402). 8. Remove the fuser cover assembly (See page 400).
3
hc2m445f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410).
Chapter 6. Removal Procedures, Adjustments 451
7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the electromagnetic clutch (See page 449). 12. Remove the left side E-ring (1) securing the turn gear (2) (Asm-Index: 4-12, page 555) and remove the gear from the turn roll assembly (3). 13. Remove the bearing from the turn roll assembly. 14. Remove the right side E-ring (5) securing the right side turn bearing (6) and remove the bearing from the turn roll assembly. 15. Slide the turn roll assembly to the left, and remove its right end from the printer frame. 16. Slide the right end of the turn roll assembly backward, and remove its left end from the printer frame.
Replacement
Reverse the Removal procedure.
5
hc2m446f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410).
Chapter 6. Removal Procedures, Adjustments 453
7. Remove the front side cover (See page 412). 8. Remove the turn in chute (See page 422). 9. Remove the turn chute assembly (See page 424). 10. Remove the controller assembly (See page 535). 11. Remove the E-ring (1) securing the right side turn bearing (2) (Asm-Index: 4-13, page 555) and remove the bearing from the printer frame. 12. Remove the E-ring (3) securing the turn gear (4) (Asm-Index: 4-12, page 555) and remove the gear from the rear roll assembly (5). 13. Remove the left side turn bearing (6) from the rear roll assembly. 14. Slide the rear roll assembly to the left, and remove its right end from the printer frame. 15. Slide the right end of the rear roll assembly to the rear, and remove its left end from the printer frame.
Replacement
Reverse the Removal procedure.
2 1
hc2m451f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 455
6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the two screws (1) securing the front in tray (2). 9. Open the front tray and pull out the front in tray together with the front tray assembly (3). 10. Flex the arm of the front in tray to release the hinge on the front tray assembly to separate the front in tray and the front tray assembly.
Replacement
Reverse the Removal procedure.
2 1 1 3
hc2m452f
4
J222 J137
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the front tray assembly (Asm-Index: 5-1, page 557).
3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and keep it open during the operation below. 4. Remove the EP cartridge (Asm-Index: 11-40, page 572). 5. Remove the two screws (1) securing the auxiliary tray bracket assembly (2) to the printer frame. 6. Press down the front bottom tray (3) (Asm-Index: 5-5, page 557). 7. Slide the auxiliary tray bracket assembly slightly to the front to release the hooks on the printer frame from the opening in the auxiliary tray bracket assembly. 8. Raise the right end of the auxiliary tray bracket and slide it slightly to the right. 9. Release the left end of the auxiliary tray bracket from the printer frame without pulling the harnesses (4) connected at the left rear of the auxiliary tray bracket. 10. Disconnect J137 of the high harness assembly (Asm-Index: 6-5, page 559) and J222 of the toner relay harness (Asm-Index: 12-18, page 575) from the auxiliary tray bracket. 11. Tilt the auxiliary tray bracket rear side up and remove it from the printer frame.
Replacement
1. 2. 3. 4. Open the front tray cover. Open the Pop up/ROS assembly and keep it open during the following steps. Press down the front bottom tray. Hold the auxiliary tray bracket assembly in one hand and hold the arm of the auxiliary tray no paper actuator (Asm-Index: 5-10, page 557) in the up position using the other hand.
5. Tilt the auxiliary tray bracket rear side up and place the left end of the bracket slightly front from the nal position holding the right end up. 6. Reconnect J137 and J222 and place the harnesses outside of the paper well area. Note: You may need to remove the MCU PWB (See page 526 or 529) to reconnect J137 and J222. After reconnection, replace the MCU PWB.
Chapter 6. Removal Procedures, Adjustments 458
7. Hold the arm of the auxiliary tray no paper actuator up and place the auxiliary tray bracket in the printer frame. 8. 9. 10. 11. Note: Ensure that the auxiliary tray no paper actuator ts into the hole in the front bottom tray. Secure the bracket to the printer frame using two screws (silver, 6mm). Replace the EP cartridge. Close the Pop up/ROS assembly. Close the front tray assembly.
hc2m453f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the auxiliary tray bracket assembly (See page 457). 3. Remove the screw (1) securing the auxiliary tray actuator holder (2) to the auxiliary tray bracket assembly (Asm-Index: 5-7, page 557).
4. Remove the actuator holder from the bracket with the no paper sensor (3) and the auxiliary tray no paper actuator (Asm-Index: 5-10, page 557) by lifting the right (sensor) end of the holder to disengage the hook (4) from the auxiliary tray bracket. 5. Disconnect J134 of the auxiliary tray no paper harness (Asm-Index: 5-12, page 557) from the auxiliary tray no paper sensor and remove the harness from the clamp on the auxiliary tray actuator holder (Asm-Index: 5-11, page 557). 6. Holding the arm of the no paper actuator (5) up, squeeze the hooks of the no paper sensor, and remove the sensor from the holder. 7. Push the actuator end (as opposed to the sensor ag end) of the actuator (5) rearwards until it snaps out of the holder.
Replacement
Reverse the Removal procedure.
2 1
J221
hc2m975f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the EP cartridge (Asm-Index: 11-40, page 572).
Chapter 6. Removal Procedures, Adjustments 462
3. To remove the entire assembly: a. Snap out the toner sensor holder (Asm-Index: 5-15, page 557). b. Disconnect P/J922 at the left side of the printer. 4. To remove just the toner sensor: a. Using a small at blade screwdriver, expand the hooks (1) on the upper side of the toner sensor holder (2) (Asm-Index: 5-15, page 557) to remove the toner sensor (3) (Asm-Index: 5-14, page 557) from the holder. b. Disconnect J221 of the toner sensor harness (Asm-Index: 5-17, page 557) from the sensor.
Replacement
Reverse the Removal procedure.
1 1
hc2m456f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray together with the front tray assembly (See page 455). 11. Remove the auxiliary tray bracket assembly (See page 457). 12. Remove the BTR assembly (See page 466) to protect it from damage. 13. Remove the controller assembly (See page 535). 14. Remove the CRU guide assembly left (See page 506). 15. Remove the CRU guide assembly right (See page 510). 16. Lift the left side of the front bottom tray (1) and pull the tray out from under the cams (2) on the ends of the pick up roll assembly (Asm-Index: 6-8, page 559). 17. Lift the left front side of the tray and slide it to the left to remove. 18. Remove the tray. 19. Remove the auxiliary tray normal force springs (3) (Asm-Index: 5-6, page 557) if necessary.
Replacement
Reverse the Removal procedure.
BTR Assembly
Asm-Index: 6-1, page 559.
hc2m461f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the front tray assembly (Asm-Index: 5-1, page 557). 3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572). Ensure that it does not close during the operations below. Attention: Do not touch the surface of the roll of the BTR assembly, the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559), or the window of the ROS assembly (Asm-Index: 11-20, page 572). 4. 5. 6. 7. Turn up the levers of the BTR assembly (1) at both ends. Holding the levers, lift the BTR upwards at a 45 degree angle. Remove the BTR from the transport chute assembly. Place the BTR on a secure surface and cover the BTR with paper so as not to contaminate or damage it.
Replacement
Reverse the Removal procedure.
J14
DTS
1
TR
2 1
J131 P/J135
J121
J124
J13
hc2m462f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 468
4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray together with the front tray assembly (See page 455). 11. Remove the fuser assembly (See page 487). 12. Remove the controller assembly (See page 535). 13. Remove the Pop up/ROS assembly (See page 500). 14. Remove the auxiliary tray bracket assembly (See page 457). 15. Carefully remove the BTR assembly (See page 466). 16. Disconnect J180 of the fuser cover harness from the duplex interface PWB (Asm-Index: 12-6, page 575). 17. Remove the duplex interface PWB (See page 524). 18. Disconnect: a. J13 and J14 of the high harness assembly (Asm-Index: 6-5, page 559) from the MCU PWB. b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of the high harness assembly to the LVPS assembly (Asm-Index: 12-4, page 575) and to the interlock switch (Asm-Index: 12-1, page 575). c. J TR and J DTS of the high harness from the HVPS (Asm-Index: 12-11, page 575). d. J131 from the registration clutch assembly (Asm-Index: 10-9, page 570). e. J135 from the pick up solenoid (Asm-Index: 6-17, page 559).
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.
3
J124
hc2m463f
Replacement
1. Place the transport chute assembly on the printer frame. Attention: Ensure the front bottom tray (Asm-Index: 5-5, page 557) is located under the pick up roll assembly (Asm-Index: 6-8, page 559) and the pick up cams (Asm-Index: 6-12, page 559) presses down the front bottom tray. 2. Secure the transport chute assembly to the printer frame using six screws (silver, collared, 10mm).
Chapter 6. Removal Procedures, Adjustments 471
3. Place the harnesses and wires to the side of the controller assembly (Asm-Index: 13-1, page 578). 4. Route all of the harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page 559) under the clamps. Attention: Route the harnesses so that they do not touch the gears. 5. Place the rear tie plate on the printer body and secure the tie plate using six screws (silver, 6mm) and two screws (gold, self tapping, 8mm). 6. Replace the MCU PWB together with the MCU holder (See page 529). 7. Reconnect: a. J13 and J14 of the high harness assembly to the MCU PWB. b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of the high harness assembly to the LVPS assembly and to the interlock switch. c. J TR and J DTS of the high harness to the HVPS. d. J131 to the registration clutch assembly. e. J135 to the pick up solenoid. 8. Replace the duplex interface PWB (See page 524). 9. Reconnect P/J180 of the fuser cover harness to the duplex interface PWB. 10. Replace the BTR assembly (See page 466). 11. Replace the auxiliary tray bracket assembly (See page 457). 12. Replace the Pop up/ROS assembly (See page 500). 13. Replace the controller assembly (See page 535). 14. Replace the fuser assembly (See page 487). 15. Replace the front in tray together with the front tray assembly (See page 455). 16. Replace the pop up cover assembly (See page 416). 17. Replace the exit cover (See page 414).
Chapter 6. Removal Procedures, Adjustments 472
18. Replace the front side cover (See page 412). 19. Replace the right cover assembly (See page 410). 20. Replace the left cover assembly (See page 406). 21. Replace the right top cover (See page 404). 22. Replace the left top cover (See page 402). 23. Replace the fuser cover assembly (See page 400).
Pick Up Roll
Asm-Index: 6-9, page 559.
hc2m465f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the auxiliary tray cover (Asm-Index: 5-2, page 557). 3. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and ensure it does not close during the operations below.
Chapter 6. Removal Procedures, Adjustments 474
4. Remove the EP cartridge (Asm-Index: 11-40, page 572). 5. Moe the auxiliary tray bracket assembly away from the rolls457), only diconnect the connectors if necessary. 6. If the rolls are not oriented as shown, you may need to rotate the shaft with the following procedure: a. Remove the controller assembly (See page 535). b. Press on the armature of the pick up solenoid (Asm-Index: 6-17, page 559) down to engage the pick up gear (Asm-Index: 6-15, page 559) with the drive. c. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up cams (Asm-Index: 6-12, page 559) are face down. Note: Repeat steps 5 hrough 7 for right and left side rolls. 7. Release the hook on the core roll (1) (Asm-Index: 6-10, page 559) from the groove on the pick up shaft, using a at blade screwdriver or nger nail. Slide the core roll away from the pick up roll (2). 8. Slide the pick up roll in the same direction as step 7 until it is clear of the drive pin on the pick up shaft. 9. Remove the pick up roll from the shaft.
Replacement
Note: Repeat steps 1 through 3 for right and left side rolls. 1. Holding the rubber side of the pick up roll up, place it on the pick up shaft on the outside of the drive pins on the pick up shaft. Attention: The arrows molded into the side of the pick up rolls show the direction of rotation. Be sure to install the rolls correctly. 2. Slide the pick up roll inside inserting the drive pins on the pick up shaft into the grooves on the roll. 3. Pressing down slightly on the retard pad assembly, (Asm-Index: 6-18, page 559), slide the core roll on the same direction as step 2, until its hook snaps into the groove on the pick up shaft.
Chapter 6. Removal Procedures, Adjustments 475
4. Replace the auxiliary tray bracket assembly (See page 457). 5. Replace the EP cartridge. 6. Close the Pop up/ROS assembly.
Pick Up Solenoid
Asm-Index: 6-17, page 559.
P/J135
2
hc2m466f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 477
4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Remove the auxiliary tray bracket assembly (See page 457). 11. Press the armature (1) of the pick up solenoid (2) down. 12. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up gear (3) (Asm-Index: 6-15, page 559) stops. 13. Press down again on the armature of the pick up solenoid. 14. Remove the pick up spring (4) (Asm-Index: 6-16, page 559) from the pick up gear and the housing of the transport chute assembly (Asm-Index: 6-2, page 559). 15. Disconnect P/J135 from the harness for the pick up solenoid. 16. Remove the screw (5) securing the solenoid on the transport chute through the opening in the left frame assembly (Asm-Index: 10-11, page 570). 17. Remove the solenoid from the transport chute through the opening in the left frame.
Replacement
1. Place the pick up solenoid in position on the transport chute assembly through the opening in the left frame assembly so that the armature of the pick up solenoid meshes with the pick up gear. 2. Secure the solenoid on the transport chute assembly through the opening in the left frame, using a screw (gold, self tapping, 8mm).
3. Reconnect P/J135 to the harness for the pick up solenoid and route the harness so that it does not interfere with the gears. 4. Replace the pick up spring between the pick up gear and the housing of the transport chute assembly. 5. Press the armature of the pick up solenoid down. 6. Rotate the rotor of the main motor clockwise until the pick up gear stops (the rubber side of the pick up rolls are face up). 7. Replace the auxiliary tray bracket assembly (See page 457). 8. Replace the MCU PWB (See page 526) together with the MCU holder. 9. Replace the duplex interface PWB (See page 524). 10. Reconnect J180 to the duplex interface PWB 11. Replace the controller assembly (See page 535). 12. Replace the front side cover (See page 412). 13. Replace the left cover assembly (See page 406). 14. Replace the left top cover (See page 402). 15. Replace the fuser cover assembly (See page 400).
1
hc2m467f
3 5
hc2m468f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the right top cover (See page 404). 4. Remove the right cover assembly (See page 410). 5. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and keep it open during the operation below. 6. Remove the auxiliary tray bracket assembly (See page 457). 7. Remove the two pick up rolls (See page 474).
8. Remove the three screws (1) securing the transport front chute (2) (Asm-Index: 6-7, page 559). 9. Release the hook on the center core roll (3) (Asm-Index: 6-10, page 559) and slide the center core roll to the right away from the retard pad assembly (4). Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft (Asm-Index: 6-13, page 559). 10. Press the retard pad assembly to the front and pull its rear side up to release the hooks on its rear side from the transport chute assembly. 11. Hold the retard pad assembly at a right angle and ensure two retard springs (5) (Asm-Index: 6-19, page 559) hang on it. 12. Remove the retard pad assembly together with the two retard springs by pressing to the front. 13. Remove the retard springs from the retard pad assembly.
Replacement
1. Open the Pop up/ROS assembly and keep it open during the operation below. 2. 3. 4. 5. 6. Note: Step 2 is applicable only when installing a new retard pad assembly. Using a small at blade screwdriver apply the grease, packed with the retard pad assembly package, to the bearing groove on the transport chute assembly. Reinstall the retard springs on the retard pad assembly. Hold the surface of the retard pad assembly at a right angle and place it in the hollow of the transport chute assembly together with two retard springs. Position the retard springs in the groove in the hollow of the transport chute assembly using a small at blade screwdriver. Press the retard pad assembly to the front tilting its rear side to insert its rear side into the hollow on the transport chute assembly until the retard pad assembly snaps in place.
7. Slide the center core roll to the left until the hook on the core roll snaps in the groove on the pick up shaft. Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft. 8. Place the right side of the transport front chute on the transport chute aligning the position hole in the front chute to the pin on the transport chute together with the grounding plate. 9. Secure the transport front chute using three screws (silver, self tapping, with washer, 8mm). 10. Replace the two pick up rolls (See page 474). 11. Replace the auxiliary tray bracket assembly (See page 457). 12. Close the Pop up/ROS assembly. 13. Replace the right cover assembly (See page 410). 14. Replace the right top cover (See page 404). 15. Replace the fuser cover assembly (See page 400).
Registration Sensor/Actuator
Asm-Index: 7-7, page 562.
P/J132
5 9 1 6 2 5 1
10
3
hc2m472f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 484
3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the fuser assembly (See page 487). 10. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it to keep it open without the force of the pop up springs in the next step. 11. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers. 12. Close the Pop up/ROS assembly. 13. Remove the controller assembly (See page 535). 14. Disconnect P/J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 15. Remove the duplex interface PWB (See page 524). 16. Remove screws below: a. Two screws (1) securing the lower part of the back of the rear tie plate (2) to the base frame assembly (Asm-Index: 10-2, page 570), b. Two screws (3) securing the left of the tie plate to the left frame assembly (Asm-Index: 10-11, page 570), c. Two screws (4) securing the right of the tie plate to the right frame assembly (Asm-Index: 10-4, page 570), and d. Two screws (5) securing the upper part of the back of the tie plate to the transport chute assembly (Asm-Index: 6-2, page 559).
Chapter 6. Removal Procedures, Adjustments 485
17. Disconnect P/J132 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration sensor (Asm-Index: 7-6, page 562). 18. Remove the screw (6) securing the registration sensor bracket (7) (Asm-Index: 7-9, page 562) to the transport chute assembly. 19. Remove the registration sensor bracket from the transport chute. 20. Press down the arm of the registration actuator and squeeze the two hooks securing the sensor (8) to the bracket to remove the registration sensor. 21. Turn the registration actuator (9) to match the cutout on its left side shaft with the opening in the frame of the registration sensor bracket. 22. Release the left side shaft of the registration actuator from the bracket. 23. Slide the actuator to the left and remove it from the bracket together with the registration spring (10).
Replacement
Reverse the Removal procedure.
Fuser Assembly
Asm-Index: 8-1, page 564.
3 2
hc2m481f
Removal
CAUTION: <2-25> High temperature; switch off the printer and allow at least 20 minutes for parts in this area to cool before handling.
hcsf0225
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover assembly (1) (Asm-Index: 1-1, page 548). 3. Loosen the two captured thumb screws (2) securing the fuser assembly (3) to the left frame assembly (Asm-Index: 10-11, page 570). 4. Lift up the fuser assembly (left end rst), removing the locking tab (4) from the locking bracket (5). Removing the fuser assembly disconnects J142.
Replacement
1. Place the fuser assembly on the top of the printer body, making sure J142 connects properly. 2. Hold the tip of the full stack actuator (Asm-Index: 8-8, page 564) so that it does not interfere with the exit cover (Asm-Index: 1-12, page 548). 3. Secure the fuser assembly to the left assembly using the two captured thumb screws. 4. Close the fuser cover assembly.
Main Motor
Asm-Index: 10-6, page 570.
J16
hc2m4a1f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 7. Remove the duplex interface PWB (See page 524). 8. Disconnect J16 of the main motor (1) from the MCU PWB (Asm-Index: 12-8, page 575). Attention: Move the main motor to keep from touching the MCU holder (Asm-Index: 12-9, page 575) during steps 9 and 10. 9. Remove the three screws (2) securing the main motor to the left frame assembly (Asm-Index: 10-11, page 570). 10. Remove the main motor from the left frame assembly.
Replacement
Attention: Move the main motor to keep from touching the MCU holder during the following step. 1. Place the main motor in the left frame assembly and secure the motor using three screws (silver, 6mm). 2. Rotate the rotor of the main motor clockwise manually, and ensure it rotates smoothly. 3. Reconnect J16 of the main motor to the MCU PWB. 4. Replace the duplex interface PWB (See page 524). 5. Reconnect J180 of the fuser cover harness to the duplex interface PWB.
Chapter 6. Removal Procedures, Adjustments 490
6. Replace the controller assembly (See page 420). 7. Replace the front side cover (See page 412). 8. Replace the left cover assembly (See page 406). 9. Replace the left top cover (See page 402). 10. Replace the fuser cover assembly (See page 400).
1 2
J131
2
hc2m4a2f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Disconnect J131 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration clutch assembly (Asm-Index: 10-9, page 570). 11. Unhook all the wires and harnesses from the clamp on the paper handling gear assembly (1). 12. Remove the three screws (2) securing the paper handling gear assembly. 13. Slightly pull out the gear assembly and release the registration clutch assembly from the drive bearing left (3) (Asm-Index: 10-8, page 570). 14. Remove the gear assembly from the left frame assembly (Asm-Index: 10-11, page 570). 15. Remove the drive bearing left from the gear assembly.
Replacement
1. Place the drive bearing left in the paper handling gear assembly. 2. Place the gear assembly in the left frame assembly inserting the shaft of the registration clutch assembly into the drive bearing left. 3. Secure the gear assembly to the left frame using three screws (silver, 6mm). 4. Hook all the wires and harnesses to the clamp on the gear assembly. Attention: Route the wires and harnesses to keep from touching the gears. 5. Reconnect J131 of the high harness assembly to the registration clutch assembly. 6. Replace the MCU PWB. 7. Replace the duplex interface PWB (See page 524). 8. Reconnect J180 of the fuser cover harness to the duplex interface PWB (Asm-Index: 12-6, page 575). 9. Replace the controller assembly (See page 535). 10. Replace the front side cover (See page 412). 11. Replace the left cover assembly (See page 406). 12. Replace the left top cover (See page 402). 13. Replace the fuser cover assembly (See page 400).
hc2m4a3f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 495
5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (Asm-Index: 12-6, page 575). 8. Remove the duplex interface PWB (See page 524). 9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575). 10. Remove the paper handling gear assembly (See page 492) together with the drive bearing left (Asm-Index: 10-8, page 570). 11. Pull out the registration clutch assembly (1) and remove it from the left frame assembly (Asm-Index: 10-11, page 570).
Replacement
Reverse the Removal procedure.
hc2m4a4f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404).
Chapter 6. Removal Procedures, Adjustments 497
5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the exit cover (See page 414). 9. Remove the pop up cover assembly (See page 416). 10. Remove the front in tray (See page 455) including the front tray assembly (Asm-Index: 5-1, page 557). 11. Remove the BTR assembly (See page 466). 12. Remove the fuser assembly (See page 487). 13. Remove the controller assembly (See page 535). 14. Remove the duplex interface PWB (See page 524). 15. Remove the MCU PWB (See page 526) together with MCU holder (Asm-Index: 12-9, page 575). 16. Remove the main motor (See page 489). 17. Remove the paper handling gear assembly (See page 492) together with the drive bearing left (Asm-Index: 10-8, page 570). 18. Remove the registration clutch assembly (See page 495). 19. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) to a right angle and hold it in your hand to keep from closing without the force of the pop up spring left/right (Asm-Index: 11-6 and 11-7, page 572) in the next step. 20. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers. 21. Close the Pop up/ROS assembly. 22. Remove the eight screws securing the rear tie plate (Asm-Index: 10-5, page 570). 23. Remove the four screws (1) securing the main gear assembly (2) to the left frame assembly (Asm-Index: 10-11, page 570).
Chapter 6. Removal Procedures, Adjustments 498
24. Slide the main gear assembly to the right and release gears and shafts from the frame. If you are having trouble removing the main gear assembly, remove the CRU guide assembly left (See page 506). 25. Pull the gear assembly up and behind to remove it from the frame.
Replacement
Reverse the Removal procedure.
Pop Up Unit
Asm-Index: 11-111-23, page 572.
2 3 8 4 7
FRONT
1 9 5 6
J12
J17
hc2m977f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the exit cover (See page 414). 7. Remove the pop up cover assembly (See page 416). 8. Remove the fuser assembly (See page 487). 9. Remove the controller assembly (See page 535). 10. Disconnect J12 of the ROS harness (Asm-Index: 12-16, page 575) and J17 of the CRU sensor assembly (Asm-Index: 11-15, page 572) from the MCU PWB (Asm-Index: 12-8, page 575). 11. Remove the ferrite core 1 (1) (Asm-Index: 12-21, page 575) from the harnesses using a small at blade screwdriver 12. Remove the screw (2) securing the pop up earth wire (3) (Asm-Index: 11-25, page 572) to the pop up frame (4) (Asm-Index: 11-1, page 572). Note: The screw securing the other end of the pop up earth wire to the left frame assembly (Asm-Index: 10-11, page 570) does not need to be removed. 13. Remove the screw (5) securing the clamp P (6) (Asm-Index: 12-22, page 575) to the left frame assembly and release the ROS harness and the harness of the CRU sensor assembly 14. Release the ROS harness and the harness of the CRU sensor assembly from the opening in the left frame.
Attention: Do not touch the surface of the BTR assembly (Asm-Index: 6-1, page 559), the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following step. 15. Open the Pop up/ROS assembly and hold it even, the spring force is released in next step. 16. Release the pop up spring left (7) /right (8) (Asm-Index: 11-6 and 11-7, page 572) from the rear tie plate (Asm-Index: 10-5, page 570). 17. Close the Pop up/ROS assembly. 18. Remove the two screws (9) securing the pop up shaft (Asm-Index: 11-2, page 572) to the left frame assembly and the right frame assembly (Asm-Index: 10-4, page 570) respectively. 19. Lift the Pop up/ROS assembly and slide it along the guide channel and remove the pop up unit from the printer frame.
Replacement
Reverse the Removal procedure. Note: Ensure that the fuser guide lever is above the metal tab of the fuser drive gear as shown in Figure 66 on page 500.
P/J171
J17
hc2m4b3f
Removal
Note: If you can access the four mounting screws, you may be able to avoid complete removal of the Pop up/ROS assembly. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the front side cover (See page 412). 7. Remove the exit cover (See page 414). 8. Remove the pop up cover assembly (See page 416). 9. Remove the fuser assembly (See page 487). 10. Remove the controller assembly (See page 535). 11. Remove the Pop up/ROS assembly (See page 500). 12. Lay the Pop up/ROS assembly upside down. 13. Release the harness of the CRU sensor assembly (1) from the clamp. 14. Release the ROS harness (Asm-Index: 12-16, page 575) from the clamp, if necessary. 15. Remove the four screws (2) securing the CRU sensor assembly to the pop up frame (Asm-Index: 11-1, page 572) and remove the sensor assembly. 16. Disconnect P/J17 from the MCU.
Replacement
Reverse the Removal procedure.
6 5
6
hc2m4b7f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Remove the controller assembly (See page 535). 10. Remove the center screw (1) of the HVPS (Asm-Index: 12-11, page 575) securing the HVPS to the CRU guide assembly left (2). 11. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the operation below. 12. Remove the two screws securing the left and right pop up latch feet (Asm-Index: 11-22, page 572) to the left and right pop up latches (Asm-Index: 11-10 and 11-11, page 572). 13. Flex the left and right pop up latches and remove the left and right pop up latch feet. 14. Open the Pop up/ROS assembly. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) or the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 15. Remove the BTR assembly (See page 466) to protect it from damage.
16. Remove the screw (3) securing the earth plate left (4) (Asm-Index: 11-32, page 572) on the top of the CRU guide assembly left. 17. Remove the screw (5) securing the upper part of the CRU guide assembly left. 18. Remove the six screws (6) securing the CRU guide assembly. 19. Press the pins on the left side of the left frame assembly (Asm-Index: 10-11, page 570) to release the guide assembly. 20. Remove the guide assembly by carefully working it away from the printer frame.
Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly or the window of the ROS assembly during the following steps. 2. Place the CRU guide assembly left on the left frame assembly inserting the pins on the guide assembly into the openings in the printer frame. 3. Secure the guide assembly using six screws (silver, 8mm). 4. Secure the upper part of the guide assembly using a screw (gold, 14mm). 5. Secure the earth plate left using a screw (silver, 6mm) 6. Replace the BTR assembly (See page 466). 7. Half close the Pop up/ROS assembly. 8. Flex the pop up latch left/right and place the left and right pop up latch foot on the latch left/right. You may rotate the latch foot to position it properly. 9. Secure the left and right pop up latch foot to the pop up latch left/right using two screws (gold, self-tapping, 10mm). 10. Close the Pop up/ROS assembly.
Attention: Ensure that the earth plate left contacts the pop up frame (Asm-Index: 11-1, page 572). 11. Secure the HVPS to the guide assembly using a screw (gold, self tapping, 8mm) on the center of the HVPS. 12. Replace the controller assembly (See page 535). 13. Replace the BTR assembly (See page 466). 14. Replace the front in tray (See page 455) together with the front tray assembly. 15. Replace the front side cover (See page 412). 16. Replace the right cover assembly (See page 410). 17. Replace the left cover assembly (See page 406). 18. Replace the right top cover (See page 404). 19. Replace the left top cover (See page 402). 20. Replace the fuser cover assembly (See page 400).
hc2m4b8f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the operation below. 10. Remove the BTR assembly (See page 466) to protect from damage. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 11. Remove the screw (1) securing the earth spring right (2) (Asm-Index: 11-33, page 572) to the CRU guide assembly right (3) and remove the spring. 12. Remove the ve screws (4) securing the rear left end and front left side of the guide assembly. 13. Press the pins on the right side of the right frame assembly (Asm-Index: 10-4, page 570) to release the guide assembly. 14. Remove the guide assembly from the printer frame.
Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROS assembly during the following steps. 2. Place the guide assembly on the right frame assembly inserting pins on the guide assembly into the openings.
Chapter 6. Removal Procedures, Adjustments 511
3. Secure the guide assembly using ve screws (silver, 8mm). 4. Secure the earth spring right to the guide assembly using a screw (gold, collared, 12mm). 5. Replace the BTR assembly (See page 466). 6. Close the Pop up/ROS assembly. Attention: Ensure that the earth spring right contacts the pop up frame (Asm-Index: 11-1, page 572). 7. Replace the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 8. Replace the front side cover (See page 412). 9. Replace the right cover assembly (See page 410). 10. Replace the left cover assembly (See page 406). 11. Replace the right top cover (See page 404). 12. Replace the left top cover (See page 402). 13. Replace the fuser cover assembly (See page 400).
Interlock Switch
Asm-Index: 12-1, page 575.
hc2m4c1f
J21 J123
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400).
Chapter 6. Removal Procedures, Adjustments 513
3. Remove the left top cover (See page 402). 4. Remove the right top cover (See page 404). 5. Remove the left cover assembly (See page 406). 6. Remove the right cover assembly (See page 410). 7. Remove the front side cover (See page 412). 8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page 557). 9. Remove the BTR assembly (See page 466) to protect it from damage. 10. Remove the controller assembly (See page 535). 11. Remove the CRU guide assembly left (See page 506). 12. Disconnect J123 of the interlock switch (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and J21 of the interlock switch on the MCU PWB (Asm-Index: 12-8, page 575) and release the harnesses from the clamps. 13. Open the Pop up/ROS assembly (Asm-Index: 11-111-23, page 572) and hold it open during the following steps. Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps. 14. Remove the screw (2) securing the interlock switch (Asm-Index: 12-1, page 575) to the left frame assembly (Asm-Index: 10-11, page 570). 15. Release the harness through the opening in the printer frame and remove the interlock switch from the frame.
Replacement
1. Open the Pop up/ROS assembly and hold it open during the operation below. Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROS assembly during the following steps. 2. Insert the harness through the opening in the left frame assembly and place the interlock switch on the frame matching the position of the pin on the frame to the hollow on the switch. 3. Secure the interlock switch to the frame using a screw (gold, 12mm). Attention: Ensure that the arm on the pop up frame presses the interlock switch when the Pop up/ROS assembly closes. 4. Reconnect J123 of the interlock switch to the LVPS and J21 of the interlock switch to the MCU PWB and attach the harnesses to the clamps. 5. Replace the CRU guide assembly left (See page 506). 6. Replace the controller assembly (See page 535). 7. Replace the BTR assembly (See page 466). 8. Replace the front in tray (See page 455) together with the front tray assembly. 9. Replace the front side cover (See page 412). 10. Replace the right cover assembly (See page 410). 11. Replace the left cover assembly (See page 406). 12. Replace the right top cover (See page 404). 13. Replace the left top cover (See page 402). 14. Replace the fuser cover assembly (See page 400).
J190
2 1 1
hc2m4c2f
J190
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 516
4. 5. 6. 7.
Remove the fan. Remove the fan duct. Using a at-bladed screwdriver, squeeze the hooks securing the switch to the printer frame. Disconnect J190 of the fuser cover harness (Asm-Index: 12-13, page 575) from the fuser cover switch (Asm-Index: 12-2, page 575) and remove the switch.
Replacement
1. 2. 3. 4. 5. Press the cover switch up into the opening until the switch snaps into place. Reconnect J190 of the fuser cover harness to the fuser cover switch. Replace the fan duct. Replace the fan. Replace the left top cover (See page 402).
6. Replace the fuser cover assembly (See page 400). Attention: Ensure that the fuser cover assembly (Asm-Index: 1-1, page 548) pushes the tab of the fuser cover switch when the cover is closed.
Fan
Asm-Index: 12-3, page 575.
J122
hc2m3c3f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J122 of the fan (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and remove the ferrite core1 (Asm-Index: 12-21, page 575) from the harness. 8. Release the harness of the fan from clamp and opening. 9. Remove the two screws (2) securing the fan to the printer frame. 10. Remove the fan.
Replacement
1. Place the fan in the printer frame so the label faces out, so that the air blows out. 2. Secure the fan to the printer frame using two screws (silver, collared, 10mm). 3. Reconnect J122 of the fan to the LVPS assembly and reinstall the ferrite core1 into the ROS harness (Asm-Index: 12-16, page 575), the harness for the CRU sensor assembly (Asm-Index: 11-15, page 572), the fuser cover harness (Asm-Index: 12-13, page 575) and the harness to the fan. 4. Route the harness of the fan hanging to clamp and passing through opening so as not to interfere with gears and without slack. 5. Replace the controller assembly (See page 535). 6. Replace the front side cover (See page 412). 7. Replace the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 519
8. Replace the left top cover (See page 402). 9. Replace the fuser cover assembly (See page 400).
LVPS Assembly
Asm-Index: 12-4, page 575.
7
J122 J127 J123
J121
4 1 2
J126
10
5 3
hc2m4C4F
Removal
Note: The small fan shown in Figure 73 may not be on later versions of the printer. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the left lower cover (See page 408). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect all the connectors from the LVPS assembly. 8. Release all the harnesses and the wire from their clamps. 9. Remove the screw (1) securing the grounding wires to the printer frame. Attention: Do not move the parts far, since the power inlet and the LVPS assembly (2) are connected by wires. 10. Remove the three screws (3) securing the inlet holder (4) (Asm-Index: 12-5, page 575) to the left frame assembly (Asm-Index: 10-11, page 570). 11. Remove the inlet holder from the printer frame together with the main power switch / power inlet (5). 12. Remove the two screws (6) securing the main power switch / power inlet of the LVPS assembly (2) to the inlet holder and remove the switch/inlet. 13. Remove the four screws (7) securing the circuit board of the LVPS assembly. 14. Carefully remove the LVPS from the printer frame by moving the LVPS slightly to the left and then lifting and pivoting the bottom of the LVPS up to clear the printer frame.
Replacement
Reverse the Removal procedure.
J180
2 1
hc2m4c5f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the fuser cover. 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB (1). 8. Remove the two screws (2) (silver, hexagon, 8mm) securing the rear end of the duplex interface PWB to the left frame assembly (Asm-Index: 10-11, page 570). 9. Pull out the duplex interface PWB to the left to disconnect P/J18 from the MCU PWB (Asm-Index: 12-8, page 575). 10. Remove the duplex interface PWB.
Replacement
Reverse the Removal procedure.
1 3
2
hc2m4c6f
Removal
Note: If possible, print a CONFIG page before replacing the MCU (see Conguration Page on page 250). After replacing the MCU, the page count value will be reset to 0. This means that the true printer page count will be the value before MCU replacement plus the value shown on the CONFIG page after replacement. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Remove the duplex interface PWB (See page 524). 7. Disconnect all the connectors from the MCU PWB (1) (Asm-Index: 12-8, page 575). 8. Remove the four screws (2). 9. Remove the MCU PWB.
Replacement
1. 2. 3. 4. 5. 6. Position the MCU PWB in the holder. Secure the MCU PWB to the frame using three screws. Secure two clamp Fs to the MCU PWB using a screw. Reconnect all the connectors to the MCU PWB. Route the harnesses to keep from touching the gears and edge of the frame. Replace the duplex interface PWB (See page 524).
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.
3 2 1 2
hc2m4c7f
Removal
Note: If possible, print a CONFIG page before replacing the MCU (see Conguration Page on page 250). After replacing the MCU, the page count value will be reset to 0. This means that the true printer page count will be the value before MCU replacement plus the value shown on the CONFIG page after replacement. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402). 4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the duplex interface PWB (See page 524). Note: The models equipped with the controller inside the printer do not use the connectors P19 and P23. The models equipped with the controller outside of the printer do not use connector P23. 8. Disconnect all the connectors from the MCU PWB (1). 9. Release all the harnesses from the clamp and the clamp Fs (Asm-Index: 12-23, page 575) on the MCU holder. 10. Remove the four screws (2) securing the MCU holder (3) to the left frame assembly (Asm-Index: 10-11, page 570). 11. Remove the MCU PWB together with the MCU holder.
Replacement
1. Keeping the harness for P/J13 to the printer frame side from the MCU PWB, place the MCU PWB on the left frame assembly together with the MCU holder. 2. Secure the MCU holder to the frame using four screws (gold, 6mm). 3. Reconnect all the connectors to the MCU PWB. 4. Hook the harnesses to the clamp and the clamp Fs on the MCU holder. 5. Route the harnesses to keep from touching the gears and edge of the frame. 6. Replace the duplex interface PWB (See page 524). 7. Replace the controller assembly (See page 535). 8. Replace the front side cover (See page 412). 9. Replace the left cover assembly (See page 406). 10. Replace the left top cover (See page 402). 11. Replace the fuser cover assembly (See page 400). Note: Steps 12 and 13 are applicable if you installed a new MCU PWB. 12. Set the NVRAM data according to the specication of the printer. 13. Reset the Toner and Fuser counters to 0 (see Counters on page 255).
HVPS
Asm-Index: 12-11, page 575.
1 3
DTS
2 3
J151
TR
3
hc2m4c8f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402). 3. Remove the left cover assembly (See page 406).
Chapter 6. Removal Procedures, Adjustments 532
4. Remove the front side cover (See page 412). 5. Remove the controller assembly (See page 535). 6. Disconnect all the connectors from the HVPS (1). Attention: Do not touch the adjustment knob on the HVPS. Do not deform the spring plate on the CRU guide assembly left (Asm-Index: 11-30, page 572). 7. Remove the screw (2) securing the center of the HVPS to the CRU guide assembly left. 8. Remove the four screws (3) securing the HVPS to the left frame assembly (Asm-Index: 10-11, page 570). 9. Remove the DTS and interlock cable holders from the front left frame. 10. Holding the adjustment knob (4) (Asm-Index: 12-12, page 575) in your ngers, remove the HVPS from the frame. 11. Remove the adjustment knob from the HVPS.
Replacement
1. Place the adjustment knob on the HVPS. Attention: Do not change the adjustments on the HVPS. Do not deform the spring attachment on the CRU guide assembly left. 2. Holding the volume knob in your ngers, place the HVPS in the left frame assembly. 3. Secure the HVPS to the frame using four screws (6mm). Attention: Ensure that the spring plate on the CRU guide assembly left touches the terminal on the HVPS. 4. Secure the center of the HVPS to the CRU guide assembly left using a screw (gold, 8mm). 5. Reconnect all the connectors to the HVPS. 6. Route harnesses to keep from touching the gears and frame edges. 7. Replace the controller assembly (See page 535).
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).
Controller Assembly
Asm-Index: 13-1, page 578.
2
J31 J31
|
3 4
hc2m4d1f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left top cover (See page 402).
Chapter 6. Removal Procedures, Adjustments 535
3. Remove the left cover assembly (See page 406). 4. Remove the front side cover (See page 412). 5. Disconnect J126 from the LVPS assembly (See Figure 73 on page 521). 6. Remove the three screws (2) securing the controller upper cover plate (3) (Asm-Index: 13-9, page 578) to the printer frame. 7. Remove the six screws (4) securing the controller assembly to the left frame assembly (Asm-Index: 10-11, page 570). 8. Remove the controller assembly so that the controller harness (Asm-Index: 13-5, page 578) passes the opening in the frame. Note: J31 is disconnected by removing the controller assembly from the left frame assembly.
Replacement
Reverse the Removal procedure.
Controller PWB
Asm-Index: 13-6, page 578.
5 3
2 5 1 4
hc2m4d2f
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the fuser cover assembly (See page 400). 3. Remove the left top cover (See page 402).
4. Remove the left cover assembly (See page 406). 5. Remove the front side cover (See page 412). 6. Remove the controller assembly (See page 535). 7. Remove the two screws (2) securing the external interface connector of the controller PWB. 8. Remove the two screws (3) securing the rear panel (4) (Asm-Index: 13-3, page 578) to the left frame assembly (Asm-Index: 10-11, page 570). 9. Remove the rear panel from the left frame assembly. 10. Remove eleven screws (5) securing the controller PWB to the frame. 11. Remove the controller PWB from the frame.
Replacement
Reverse the Removal procedure.
45
Notch
Notch
DRAM SIMMs
hc2m133F
Removal
Attention: Follow the instructions for handling static-sensitive devices described on page 20. 1. Switch off printer power and unplug the power cord from the wall. 2. Remove the left cover assembly (See page 406). 3. Locate the correct socket group for the type of SIMM you are installing. There are two socket groups: one contains three sockets, the other contains four sockets. The DRAM SIMMs (memory) must are in one of
the sockets in the socket group of three. The IPDS SIMM and the ash memory SIMMs (including the Controller SIMM with the operating system, PCL and PS) are in one of the sockets in the socket group of four. SIMMs should be loaded from the left to the right but the position of the SIMM within the group of sockets does not matter. 4. Using your thumbs, press with even pressure on both ends of the clips until the SIMM is released. Pivot the SIMM 45 degrees and remove it from the socket.
Replacement
Reverse the Removal procedure.
hc2m134F
Removal
Attention: Follow the instructions for handling static-sensitive devices described on page 20. 1. Switch off printer power and unplug the power cord from the wall. 2. Move to the back of the printer. Two slots for interface cards are located at the right side of the back of the printer. 3. Loosen and remove the thumbscrews that hold the network interface cards. 4. Slide the card from the slot guides, pulling slowly, and remove it from the printer.
Replacement
Reverse the Removal procedure.
Preventive Maintenance
There is no preventive maintenance for the IBM InfoPrint 20.
Usage Kit
The parts included in this kit should all be replaced approximately every 200K prints. The failure of these parts can impair printer performance. The customer is responsible for replacing the Usage Kit. See Appendix B. Supplies on page 591 for ordering information and part numbers. See the IBM InfoPrint 20: Users Guide for replacement instructions.
Reconditioning Kit
There is no reconditioning kit for the IBM InfoPrint 20.
543
544
Assembly-Index
All parts of assembly number 1 are listed in this column. The numbers 1, 2, 3, and 4, and so forth refer to the corresponding numbers in the illustration for this assembly. Index number 2, part number 90H0001, is a subassembly of assembly 1. Notice that index number 2 includes two parts, 3 and 4. These parts cannot be ordered individually. If one is needed, order the subassembly, index number 2.
Grid
Each parts illustration is divided into grids. The grids are labeled A, B, C, and D vertically and 1, 2, and 3 horizontally. The combination of a vertical grid (such as C) and a horizontal grid (such as 1) provides the coordinates C1. The index number of the part will be located in the C1 area.
Part Number
This is the IBM part number. NP (non procurable) means the part or assembly cannot be ordered.
Units
The number in this column represents the number of usages of that part in this assembly.
Description
This is a description of the assembly or part.
hc2m301F
1 (with 2-24)
hc2m302F
hc2m303F
hc2m304F
7 (with 8-17)
hc2m305F
8 (with 9-13)
hc2m306F
hc2m307F
28
A A
10 (with 11-14)
27
B B
26
C C
hc2m308F
hc2m309F
hc2m310F
20 (with 1-23)
A A
20A
C C
hc2m311F
43
42
hc2m312F
8 3
5
hc2m313F
Tools
There are no special tools required to service the IBM InfoPrint 20.
Appendix A. Features
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589 Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
Standard Features
v v v v v v v v v v Printing speed of up to 20 pages per minute Resolution of 600 dots per inch (dpi), switchable to 1200 dpi emulation PCL5e support Adobe PostScript 3 4MB of memory Parallel interface (IEEE Std 1284-1994) 500-sheet paper tray 150-sheet auxiliary tray 500-sheet paper output bin Printer drivers
Optional Features
Feature Duplex Unit Paper Drawer/500-Sheet A4/Letter Paper Drawer/500-Sheet A3/Ledger 500-Sheet Tray - A4/Letter Copyright IBM Corp. 1998 Feature Number 4402 4501 4502 4503 Part Number 90H0716 90H0717 90H3341 90H0718
589
Feature 500-Sheet Tray - A3/Ledger 2,000 Sheet Input Drawer Envelope Tray Network Card for Token-Ring Network Card for Ethernet IBM IPDS SIMM IBM Coax SCS Interface IBM Twinax SCS Interface 4MB Memory SIMM 8MB Memory SIMM 16MB Memory SIMM 32MB Memory SIMM 2MB Flash Memory 4MB Flash Memory Hard Drive PC Parallel Cable Software CD Kit Operator Panel Overlays 6 ft US (Chicago) Line Cord Japanese Heisei Font PAGES & ESC/P SIMM
Feature Number 4504 4620 4511 4120 4161 4820 4171 4141 4304 4308 4316 4332 4030 4032 4320
Part Number 90H0719 90H0720 90H0721 06L9835 06L9838 90H0746 06L9846 06L9849 63H2463 63H2465 63H2467 63H2469 63H2443 63H2444 90H0610 63H1956 90H0749 90H3335 6952301
4810 4840
07L0012 11L6578
Appendix B. Supplies
Ordering Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592
Ordering Supplies
In the U.S.A. or Canada, order printing supplies from IBM Printer Supplies, 1-888-IBM PRINT (1-888-426-7746). In v v v v v v v v Europe, call IBM Supplies Fulllment Operations at 31-43-3502756, or at one of the following numbers: Denmark: 80015534 Finland: 08001-13110 France: 05-905871 Germany: 0130 818005 Italy: 1-678 78349 Norway: 800-11389 Sweden: 020-794270 United Kingdom: 0800-968679
591
Part Numbers
The customer is responsible for buying and replacing the following supplies.
Supply EP (Toner) Cartridge Usage Kit (100 Volt) Usage Kit (110 Volt) Usage Kit (230 Volt) Average Yield 14,000 impressions 200,000 impressions 200,000 impressions 200,000 impressions Part Number 90H0748 90H3465 90H0750 90H0751
Notes: 1. For the EP (Toner) cartridge and usage kits, the approximate average yield has been established with a coverage of 5 percent. An impression is dened as one side of a printed letter-size page with a 1/2 border around the page. A duplex page is dened as two impressions. A toner cartridge can print approximately 14,000 pages of Letter-size paper, containing text or graphics that cover 5% of the page. Depending on the type of printing you do, you can obtain up to double the page yield if you use the ECONO setting for the QUALITY item on the Cong Menu or if you select toner saver print quality mode from your printer driver. (Note that the driver setting will override the menu setting.) For example, using ECONO and a density setting of 1, you may be able to print up to 28,000 images at 5% coverage. Note: The actual page yield is affected by the environment, the type of print media, the percentage of text and graphics, the complexity of the graphics, and other factors. 2. The usage kit includes a fuser assembly and transfer charging (BTR) roller assembly.
593
3. Use the auxiliary tray to print transparencies or labels. Do not feed these types of print media from the paper trays. 4. Some recycled papers release paper dust that can accumulate and cause frequent paper jams and reduced supplies life. 5. High humidity can damage paper. Try to store paper where it is cool and dry.
595
Style A3
Duplex
Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm Custom forms Minimum: 3.5 x 5.8 in 88 x 148 mm Maximum: 13 x 20 in 330 x 508 mm
No
No
Yes
No
No
Yes
No
Yes
No
Envelopes and Postcards Japanese Official Postcard (Hagaki) 3.94 x 5.83 in 100 x 148 mm Monarch 3.875 x 7.5 in 98.4 x 190.5 mm COM10 4.125 x 9.5 in 104.8 x 241.3 mm No Yes No No Yes No No Yes No
596
Style C5
Duplex
DL 4.33 x 8.66 in 110 x 220 mm Custom envelopes Minimum: 3.5 x 5.8 in 88 x 148 mm Maximum: 13 x 20 in 330 x 508 mm
No
Yes
No
No
Yes
No
597
Not supported
No
No
Yes
Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm
No
No
Yes
Not supported
No
No
Yes
Not supported
Yes
Yes
No
Yes
Yes
No
LTR Paper Group Style A5 5.85 x 8.27 in 148.5 x 210 mm Size Duplex Not supported SEF LEF No
A3 11.69 x 16.54 in 297 x 420 mm Executive 7.25 x 10.25 in 184.2 x 266.7 mm Statement 5.5 x 8.5 in 139.7 x 215.9 mm
Yes
Yes
No
Yes
Yes
No
No
No
Yes
Not supported
No
No
Yes
Not supported
601
602
Obtaining Documents, Drivers, and Utilities from the World Wide Web
To obtain current versions of the InfoPrint 20 documentation, printer drivers, utilities, and programs, the customer can do the following: 1. Access the IBM Printing Systems Company home page:
http://www.printers.ibm.com
2. Navigate to the document, printer driver, utility, or program needed and follow the instructions to download it.
2. Navigate to the code update needed and follow the instructions to download it.
. . . . . . . . . . Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.607 .607 .608 .610 .614 .615 .615 .616 .616 .617 .618 .618 .619 .619 .620 .621 .622 .622 .623 .623 .624 .625 .626 .626 .627 .627 .628 604
Duplex Cover Switch1 . Removal . . . . . . . Replacement. . . . . Duplex Cover Switch2 . Removal . . . . . . . Replacement. . . . . Duplex Pass Sensor . . Removal . . . . . . . Replacement. . . . . Duplex Stack Sensor . Removal . . . . . . . Replacement. . . . . Duplex Stack Actuator . Removal . . . . . . . Replacement. . . . . Offset Guide Arm . . . Removal . . . . . . . Replacement. . . . . Offset Assembly . . . . Removal . . . . . . . Replacement. . . . . Duplex Upper Roll . . . Removal . . . . . . . Replacement. . . . . Duplex Lower Roll . . . Removal . . . . . . . Replacement. . . . . Duplex Motor . . . . . Removal . . . . . . . Replacement. . . . .
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.629 .629 .630 .631 .631 .632 .633 .633 .634 .635 .635 .636 .637 .637 .638 .639 .640 .640 .641 .641 .643 .645 .645 .646 .648 .648 .649 .650 .651 .651
Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652 Assembly 30: Duplex Unit and Offset Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652 Assembly 31: Duplex Unit and Offset Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655
Diagnostics
If the problem involves only duplex printing, install a new duplex unit.
3.
1.
2.
3.
4.
DUPLEX UNIT The original duplex unit was a. Install a new (or borrowed) duplex unit. Note: The printer can probably continue to be used without the duplex bad. unit if a new duplex unit is needed but not immediately available. b. Repeat the D21 test Is the sensor OK? FULL STACK SENSING WITHOUT THE DUPLEX UNIT Go to Step 6 a. Remove the duplex unit. b. Repeat D21, activating the base Full Stack Actuator (at the fuser asm).
5.
The only component shared by the Full Stack sensor and the Duplex Full Stack Sensor circuits is the MCU. Install a new MCU.
Install a new Duplex Interface PWB (See page 615). Ensure that the connection at the MCU is completely seated- it can look connected when it is not. 6. Is the problem xed?
Verify the x. Also Install a new MCU verify that the problem job prints.
612
7.
Wiring Diagram
OFFSET MOTOR
M
P/J196
DUPLEX MOTOR
M
P/J197
P/J195
P/J 192
P/J186
P/J187
P/J 193
P/J 184
DUPLEX PWB
P183
P/J 198
MCU
P182
P/J 18
P/J 20
HC2M815F
3
J182
hc2m758F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Disconnect J182 of the duplex cable (Asm-Index: 30-23, page 652) from the rear of the base engine. 3. Remove the paper weight (1) (Asm-Index: 30-30, page 652) from the duplex front cover (2) (Asm-Index: 30-7, page 652). 4. Loosen the two knurled screws (3) on the back side of the duplex unit. 5. Lift the duplex unit up back and remove it from the base engine. 6. Lay the duplex unit on a at surface holding inside up.
Replacement
Reverse the Removal procedure.
3 3
J182
hc2m759F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. 4. 5. 6. Remove the E-ring (1) holding the left side knurled screw (2). Loosen (do not remove) the two screws (3) securing the duplex left cover (4). Place the duplex unit on a at surface left side up. Tilt the duplex left cover backward and loosen the hook (5) of the left cover from the frame of the duplex unit. 7. Remove the cable from the slot in the left end cover. 8. Lift the left cover and remove it from the duplex unit. 9. Lay the duplex unit on a at surface inner side up.
Replacement
Reverse the Removal procedure.
5 4 2
3 1
hc2m760F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615).
3. 4. 5. 6.
Remove the E-ring (1) holding the right side knurled screw (2). Loosen (do not remove) the two screws (3) securing the duplex right cover (4). Place the duplex unit right side up. Open the duplex lower cover (Asm-Index: 30-6, page 652).
7. Tilt the duplex right cover backward and loosen the hook (5) of the right cover from the frame of the duplex unit. 8. Lift the right cover and remove it from the duplex unit. 9. Close the lower cover. 10. Lay the duplex unit on a at surface inside up.
Replacement
Reverse the Removal procedure.
2 1
hc2m761
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Hold the duplex upper cover (1) half open. 3. Remove the duplex straps (2) (Asm-Index: 30-22, page 652) from the duplex unit (Asm-Index: 30-1, page 652). 4. Slide the upper cover to the left up, and release the right side hinge boss from the frame of the duplex unit pressing the arm inside using a at blade screwdriver, if necessary. 5. Remove the left side hinge boss from the frame.
Replacement
Reverse the Removal procedure.
1
hc2m762F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Hold the duplex lower cover (1) half open. 3. Slide the lower cover to the left up, then remove the right side hinge boss from the frame of the duplex unit (Asm-Index: 30-1, page 652) pressing the arm inside using a at blade screwdriver, if necessary.
Replacement
Reverse the Removal procedure.
Offset Motor
Asm-Index: 30-21, page 652.
hc2m764F
2
J186
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Disconnect the J186 of the offset motor (1) (Asm-Index: 30-21, page 652) from the duplex PWB (Asm-Index: 30-10, page 652). 5. Place the duplex unit left side up. 6. Remove the two screws (2) securing the offset motor. 7. Remove the motor from the frame of the duplex unit tilting the motor slightly to the right so that the lever leaves the offset guide arm (Asm-Index: 30-20, page 652).
Replacement
Reverse the Removal procedure.
Duplex PWB
Asm-Index: 30-10, page 652.
J182
2 2
J183
J187 J184
1 2
hc2m765F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617).
Appendix E. Duplex Unit Option 627
4. Remove the offset motor (See page 625). 5. Disconnect P/Js below from the duplex PWB (1). v J183 of the duplex sensor harness (Asm-Index: 30-15, page 652) v J184 of the duplex sensor harness (Asm-Index: 30-15, page 652) v J187 of the duplex motor harness (Asm-Index: 30-14, page 652) 6. Remove the four screws (2) securing the duplex PWB and remove it from the frame of the duplex unit.
Replacement
Reverse the Removal procedure.
J193
hc2m766F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Open the duplex upper cover (Asm-Index: 30-5, page 652).
Appendix E. Duplex Unit Option 629
3. Nip the duplex cover switch 1 (1) in a vertical direction and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652). Attention: Be careful not to damage the duplex sensor harness (Asm-Index: 30-15, page 652). 4. Disconnect J193 of the duplex sensor harness from the switch.
Replacement
1. 2. 3. 4. 5. Open the duplex upper cover. Reconnect J193 of the duplex sensor harness to the duplex cover switch1. Push the switch into the opening in the frame until the switch snaps in place. Route the wires of the harness inside the frame of the duplex unit. Close the duplex upper cover. Note: Ensure that the tab on the duplex upper cover presses the switch.
J198
1
hc2m767F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Disconnect J198 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex cover switch 2 (1). 4. Remove the duplex lower cover (See page 623).
5. Nip the duplex cover switch2 in a vertical direction from the back side of the duplex unit (Asm-Index: 30-1, page 652), using a needle nosed pliers if necessary, and pull the switch out from the frame of the duplex unit.
Replacement
1. 2. 3. 4. 5. Lay the duplex unit back side up. Push the duplex switch2 into the opening in the frame of the duplex unit until the switch snaps in place. Reconnect J198 of the duplex sensor harness to the switch. Route the wires of the harness inside of the frame of the duplex unit. Reinstall the duplex lower cover (See page 623).
6. Close the duplex lower cover (Asm-Index: 30-6, page 652). Note: Ensure that the tab of the duplex lower cover presses the duplex cover switch2. 7. Reinstall the duplex unit (See page 615).
hc2m768F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Disconnect J195 from the duplex pass sensor (1). 4. Nip the hooks of the sensor and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652).
Replacement
1. Lay the duplex unit inside up. 2. Push the duplex pass sensor into the hole in the frame until the sensor snaps in place. 3. Reconnect J195 to the sensor. Note: Ensure that the harness wires are in the hanger. 4. Reinstall the duplex unit (See page 615).
hc2m769F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621). 3. Remove the duplex unit (See page 615). 4. Remove the duplex left cover (See page 617). 5. Remove the duplex right cover (See page 619). 6. Remove the duplex front cover. 7. Lay the duplex unit (Asm-Index: 30-1, page 652) inside up on a pillow so that the actuator of the duplex pass sensor (Asm-Index: 30-13, page 652) does not touch the oor.
8. Disconnect J192 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex stack sensor (1). 9. Nip the hooks of the stack sensor and remove it from the duplex eliminator assembly (Asm-Index: 30-16, page 652).
Replacement
1. Lay the duplex unit inside up on a pillow so that the actuator of the duplex pass sensor does not touch the oor. 2. Push the duplex stack sensor into the opening until the sensor snaps in place. 3. Reconnect J192 of the duplex sensor harness to the sensor. 4. Route the wires of harness into the frame of the duplex unit. 5. Reinstall the duplex front cover. 6. Reinstall the duplex right cover (See page 619). 7. Reinstall the duplex left cover (See page 617). 8. Reinstall the duplex unit (See page 615). 9. Reinstall the duplex upper cover (See page 621).
hc2m770F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove duplex unit (See page 615). 3. Lay the duplex unit inside up. 4. Nip the center of the bar of the duplex stack actuator (1) using a needle nosed pliers and pull the bar to ex it. 5. Remove the right end of the bar (opposite side of the duplex stack sensor) (Asm-Index: 30-17, page 652) from the hole on the frame of the duplex eliminator assembly (Asm-Index: 30-16, page 652).
6. Turn the lever of the actuator up so that the shielding ag of the actuator leaves from the stack sensor. 7. Slide the actuator to the right and remove the bar from the hole of the duplex eliminator.
Replacement
Reverse the Removal procedure.
hc2m772F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621). 3. Remove duplex unit (See page 615). 4. Remove duplex left cover (See page 617). 5. Lay the duplex unit inside up on a pillow so that the duplex pass sensor (Asm-Index: 30-13, page 652) does not touch the oor. 6. Tilt the lever of the offset motor (Asm-Index: 30-21, page 652) toward the outside of the duplex unit. 7. Remove the screw (1) securing the offset guide arm (2). 8. Slide the offset guide arm slightly toward the front so that it leaves the lever of the offset motor and remove the arm from the frame.
Replacement
Reverse the Removal procedure.
Offset Assembly
Asm-Index: 31-6, page 655.
1
2 1
hc2m773F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex upper cover (See page 621).
3. Remove the duplex unit (See page 615). 4. Remove the duplex left cover (See page 617). 5. Remove the duplex right cover (See page 619). Note: Step 6 is applicable only to the models without the offset function. 6. Remove the offset hold arm. Note: Step 7 is applicable only to the models with the offset function. 7. Remove the offset guide arm (See page 639). 8. Lay the duplex unit top side down. 9. Remove the two screws (1) securing the duplex support assembly (2) (Asm-Index: 31-4, page 655). 10. Remove the duplex support assembly together with the duplex guide (Asm-Index: 30-8, page 652). 11. Slide the offset assembly (3) right and left and remove the four bearings (4) from the frame of the duplex unit. 12. Lift the right end of the offset assembly in the direction of the cutout in the frame and release the two shafts from the frame of the duplex unit. 13. Slide the offset assembly to the right and remove it with the four duplex bearings (Asm-Index: 31-10, page 655) and two offset gears (5) (Asm-Index: 31-22, page 655) from the frame.
3 4
hc2m774F
Replacement
1. 2. 3. 4. Lay the duplex unit top side down. Turn the duplex stack actuator so that the tip of the lever directs to the top of the duplex unit. Hold the shafts of the offset assembly with the gear side to the right. Set two duplex bearings and the offset gear to each shaft in the order below from left side of the shaft. v duplex bearing - (collar right) v duplex bearing - (collar left) v offset gear - (collar left) 5. Insert the left ends of the shafts of the offset assembly into the openings in the frame of the duplex unit. 6. Insert the right side of the shafts of the offset assembly placing the four bearings inside and two gears outside of the frame making sure that the gear collars are on the inside of the large gear (See Figure 99 on page 650).
7. Slide the body of the left side bearings and insert them into the openings in the frame until the collars touch the frame. 8. Place the left side of the duplex support assembly so that its left end xes the left side bearings. 9. Slide the body of the right side bearings and insert them into the openings in the frame until the collars touch the frame. 10. Place the right side of the duplex support assembly. 11. Secure the duplex support assembly using two screws (silver, 6mm). Note: Step 12 is applicable only to the models without the offset function. 12. Reinstall the offset hold arm. Note: Step 13 is applicable only to the models with the offset function. 13. Reinstall the offset guide arm (See page 639). 14. Reinstall the duplex right cover (See page 619). 15. Reinstall the duplex left cover (See page 617). 16. Reinstall the duplex chute (See page 615). 17. Reinstall the duplex upper cover (See page 621).
J195
hc2m775F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Remove the duplex right cover (See page 619). 5. Lay the duplex unit inside up. 6. Disconnect P/J195 from the duplex pass sensor (Asm-Index: 30-13, page 652). 7. Release the harness from the harness collar (Asm-Index: 31-24, page 655).
Appendix E. Duplex Unit Option 645
8. Remove the harness collar from the duplex upper roll. 9. Remove the left side clamp securing the duplex upper roll. 10. Remove the synchronize belt (Asm-Index: 31-16, page 655). 11. Remove the left side duplex collar (Asm-Index: 31-15, page 655). 12. Remove the pulley gear (Asm-Index: 31-14, page 655). 13. Remove the duplex gear D (Asm-Index: 31-18, page 655). 14. Remove the right side duplex collar and the duplex bearing (Asm-Index: 31-13, page 655). 15. Slide the duplex upper roll to the right and release the right side duplex bearing from the frame of the duplex unit. 16. Lift the right end of the duplex upper roll and remove its right end from the frame. 17. Slide the upper roll to the right and pull out its left end from the frame. 18. Release the hooks and the E-clip of the one way gear (Asm-Index: 31-17, page 655) using a small at blade screwdriver and remove the gear and the bearing from the shaft.
Replacement
1. 2. 3. 4. 5. 6. 7. 8. 9. Lay the duplex unit inside up. Hold the shaft of the duplex upper roll with the gear side left. Insert the left end of the shaft of the upper roll into the opening in the frame of the duplex unit. Place right end of the shaft of the upper roll into the cutout in the frame. Place the duplex bearing (collar right) to the shaft from the outside of the frame. Insert the body of the right side duplex bearing into the opening of the frame. Place the one way gear from the right side end of the duplex upper roll until the gear snaps into place. Slide the upper roll to the left. Place the duplex bearing, the duplex collars and the pulley gear on the shaft of the upper roll from the left side of the frame, in the order below.
v duplex bearing (collar left) v duplex collar v pulley gear v duplex collar Secure the collars, etc. to the upper roll using a clamp. Reinstall the synchronize belt. Reinstall the harness collar to the duplex upper roll. Hook the harness of the duplex pass sensor to the harness collar. Reconnect P/J195 to the duplex pass sensor. Reinstall the duplex right cover (See page 619).
hc2m776F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex left cover (See page 617). 4. Remove the duplex right cover (See page 619). 5. Lay the duplex unit inside up. 6. Remove the left side clamp securing the duplex lower roll.
Appendix E. Duplex Unit Option 648
7. Remove the synchronize belt (Asm-Index: 31-16, page 655). 8. Remove the left side duplex collar (Asm-Index: 31-15, page 655), the pulley gear (Asm-Index: 31-14, page 655), and the right side duplex bearing (Asm-Index: 31-13, page 655). 9. 10. 11. 12. 1. 2. 3. 4. 5. 6. 7. Slide the duplex lower roll to the right and release the right side duplex bearing from the frame. Lift the right end of the lower roll and remove its right end from the frame. Slide the lower roll to the right and pull out its left end from the frame. Release the E-ring and remove the duplex bearing from the right end of the shaft.
Replacement
Lay the duplex unit inside up. Hold the shaft of the duplex lower roll with the pulley gear side left. Insert the left end of the shaft of the lower roll into the opening in the frame of the duplex unit. Insert the duplex bearing (collar right) to the shaft of the lower roll from the right end. Secure the bearing using an E-ring. Place the right end of the shaft of the lower roll placing the duplex bearing outside of the frame. Place the left side duplex bearing, the duplex collars and the pulley gear on the lower roll from the outside of the frame, in the order below. v duplex bearing (collar left) v duplex collar v pulley gear v duplex collar 8. Secure the duplex collar, etc. to the lower roll using a clamp. 9. Reinstall the synchronize belt. 10. Reinstall the duplex right cover (See page 619). 11. Reinstall the duplex left cover (See page 617).
Duplex Motor
Asm-Index: 31-23, page 655.
2 1
2 J197
hc2m777F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the duplex unit (See page 615). 3. Remove the duplex right cover (See page 619). 4. Lay the duplex unit inner side up. 5. Disconnect J197 of the duplex motor harness (Asm-Index: 30-14, page 652) from the duplex motor (1). 6. Remove the two screws (2) securing the motor. 7. Remove the duplex motor.
Replacement
Reverse the Removal procedure.
hc2m755F
Table 84. Assembly 30: Duplex Unit and Offset Feeder I (continued)
Asm Index 30 20 21 22 23 30 B1 B1 A3 C1 A2 90H3371 90H3372 90H3373 90H3374 90H3375 1 1 1 1 1 Grid Part Number Units Duplex unit and offset feeder I v Offset guide arm v Offset motor v Duplex strap v Duplex cable v Paper weight Description
2
C
25 25 25
hc2m756F
14 15 16 17 18
2 2 1 1 1
v Pulley gear (in kit P/N 11L5321) (see page 580) v Duplex gear (in kit P/N 11L5321) (see page 580) v Sync belt v One-way gear (in kit P/N 06L9998) (see page 580) v Duplex gear D (in kit P/N 06L9998) (see page 580)
Table 85. Assembly 31: Duplex Unit and Offset Feeder II (continued)
Asm Index 31 19 20 21 22 23 24 25 C4 B4 B4 A3, A4 B4 B2 C1, C2 90H3379 NP NP 1 3 1 2 1 1 ? Grid Part Number Units Duplex unit and offset feeder II v Duplex gear C (in kit P/N 06L9998) (see page 580) v Duplex gear B (in kit P/N 06L9998) (see page 580) v Duplex gear A (in kit P/N 06L9998) (see page 580) v Offset gear (in kit P/N 06L9998) (see page 580) v Duplex motor v Return chute assembly v Clip Description
658
Parts Catalog
1 2 3 4
25
C C
hc2m509F
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.663 .663 .663 .664 .664 .665 .666 .666 .667 .667 .668 .668 .669 .670 .670 .671 .672 .673 .673 .674 .674 .675 .676 .676 .677 .678 .678 661
Replacement. . . . . . . . . Cassette Guide Assembly L . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette No Paper Sensor . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette Guide Assembly R . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Cassette No Paper Actuator . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roll . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Solenoid . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Electromagnetic Clutch Aux. . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Turn Roll Assembly . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Parts Catalog . . . . . . . . . . Assembly 20: Optional Tray 2/3 Assembly 21: Optional Tray 2/3
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I . II .
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.679 .680 .681 .681 .683 .683 .684 .685 .685 .686 .687 .687 .688 .689 .689 .690 .691 .691 .692 .693 .693 .694 .695 .695 .696 .697 .697 .700
16 TRAY n MISSING
Meaning: Paper Cassette (Tray 1), Tray 2 and/or Tray 3 are not in place. Action: Open and close the tray. If you have not installed the tray, do so at this time.
Table 88. 16 TRAY n MISSING
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No
21 PAPER JAM
Use this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.
Table 90. 21 PAPER JAM
Step Actions and Questions SUSPECT COMPONENTS v Connection to the tray above the option v 500 Sheet Feeder (Asm-Index: 20-1, page 697) v If failing option is in the Tray 2 position: Tray 1 Feeder PWB (Asm-Index: 3-1, page 553) Yes No
Wiring Diagram
P207 P/J P/J 904 204
FEED SOLENOID CASSETTE NO PAPER SENSOR
FEEDER PWB
P201
P/J 205
FEEDER PWB
P201
P/J 205
P207
MCU
P202
FEEDER PWB
P201
P/J 18
P/J 20
HC2M858F
2
hc2m707F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the base engine and the feeder assembly. 3. Remove the two screws (1), using a stabilizer screwdriver, securing the feeder assembly to the base engine.
Replacement
1. Rotate the feed roll (Asm-Index: 21-11, page 700) until its rubber surface faces up.
2. Lift the base engine and place it on the feeder assembly positioning the holes in the base engine to the bosses (2) on the feeder assembly. Attention: Move the base engine horizontally and slowly. 3. Using a stabilizer screwdriver, secure the base engine to the feeder assembly using the two screws.
3
hc2m708F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Remove the screw (1) securing the feed housing left (2) to the cassette guide assembly left (Asm-Index: 20-16, page 697). 4. Remove the four screws (3) securing the feed housing to the feeder assembly. 5. Remove the housing.
Replacement
Reverse the Removal procedure.
hc2m709F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Remove the screw (1) securing the feed housing right to the cassette guide assembly right (2) (Asm-Index: 20-23, page 697).
Appendix G. 500-Sheet Paper Tray Option 670
4. Remove the four screws (3) securing the feed housing to the feeder assembly. 5. Remove the feed housing.
Replacement
Reverse the Removal procedure.
3 3
hc2m710F
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.
Feeder PWB
Asm-Index: 20-11, page 697.
J202
J201
1
J203
2
hc2m711F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Disconnect J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB.
Attention: Do not move the feeder PWB away from the feeder assembly (Asm-Index: 20-1, page 697). They are still connected by harnesses. 4. Remove the four screws (1) securing the feeder PWB (2) to the feeder assembly. 5. Disconnect J201 of the tray upper harness (Asm-Index: 20-27, page 697) and /J202 of the tray lower 2 harness (Asm-Index: 20-12, page 697) from the feeder PWB. 6. Remove feeder PWB from the feeder assembly.
Replacement
1. Reconnect J201 of the tray upper harness and J202 of the tray lower 2 harness to the feeder PWB. Attention: Do not damage the paper size switch on the feeder PWB during step 2. 2. Place the feeder PWB on the feeder assembly. 3. Secure the feeder PWB to the feeder assembly using four screws (silver, 6mm). 4. Reconnect J203 of the feeder harness to the feeder PWB. 5. Route the harnesses so as not to interfere with the function of the paper Size switch. 6. Reinstall the feed housing left (See page 668).
Turn In Chute
Asm-Index: 20-14, page 697.
1
hc2m712F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697). 3. Open the turn chute assembly aux (1). (Asm-Index: 20-15, page 697). 4. Flex the left side arm of the turn in chute (2) and remove its hinge hole from the boss on the cassette guide assembly left (Asm-Index: 20-16, page 697). 5. Remove the turn in chute from the cassette guide assembly right (Asm-Index: 20-23, page 697).
Appendix G. 500-Sheet Paper Tray Option 676
Replacement
Reverse the Removal procedure.
hc2m713F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the turn in chute (See page 676). 3. Hold the chute assembly open and slide it to the left. 4. Lift the rear of the feeder assembly (Asm-Index: 20-1, page 697) and pull the right side of the turn chute down. 5. Slide the chute to the right and remove it from the feeder assembly. 6. Lower the feeder assembly.
Appendix G. 500-Sheet Paper Tray Option 678
Replacement
Reverse the Removal procedure.
3 2
J203 J204
2
J206
1
hc2m714F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678). 5. Disconnect: v J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB (Asm-Index: 20-11, page 697) v J204 from the feed solenoid (Asm-Index: 21-18, page 700) v J206 of the feeder harness connecting to the electromagnetic clutch aux. (Asm-Index: 21-19, page 700) Release the clutch side of the feeder harness from the clamp. Release the three screws (1) securing the cassette guide assembly L (2) from outside of the frame. Remove the screw (3) securing the cassette guide from the front bottom inside the cassette well. Using a at blade screwdriver, push the three hooks (4) at the bottom of the cassette guide assembly L, up and in, one by one, to release them from the frame. 10. Tilt the cassette guide, pulling its bottom edge from the inside of the cassette well. 11. Ensure that the three upper hooks of the cassette guide are released from the frame. 12. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator (Asm-Index: 20-26, page 697) 13. Push all harnesses on the cassette guide to free them from the frame. 14. Remove the cassette guide from the feeder assembly. 6. 7. 8. 9.
Replacement
1. Hold the cassette guide assembly left with the bottom to the right and top to the left so that it will not interfere with the cassette no paper actuator.
Appendix G. 500-Sheet Paper Tray Option 681
2. 3. 4. 5. 6. 7. 8. 9.
Insert the cassette guide into the paper cassette well. Insert all connectors on the cassette guide through their openings in the frame. Place the upper three hooks of the cassette guide in their respective holes in the frame. Pull the feeder harness through the opening in the frame to keep them from being pinched between the cassette guide and the frame. Press the bottom of the cassette guide, tilting it up until the upper and lower hooks lock into position. Secure the cassette guide to the feeder assembly using three screws (gold, self tapping, 8mm). Insert harnesses to clamps. Reconnect: v J203 of the feeder harness to the feeder PWB v J204 to the feed solenoid v J906 of the feeder harness connecting to the electromagnetic clutch aux.
Attention: Route the harnesses so as not to interfere with the gears. 10. Ensure the cassette no paper actuator functions properly. 11. Reinstall the turn chute assembly aux. (See page 678). 12. Reinstall the turn in chute (See page 676). 13. Reinstall the feed housing left (See page 668).
J205
hc2m715F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676).
4. Swing the armature (1) of the cassette no paper actuator (Asm-Index: 20-26, page 697) to the rear so that the actuator is away from the cassette no paper sensor (2). 5. Open the turn in chute (Asm-Index: 20-14, page 697). 6. Use a small at blade screwdriver to release the hooks of the no paper sensor, located at the inside of the feeder assembly (Asm-Index: 20-1, page 697) (work from the rear of the frame), from the feeder assembly. Attention: Do not move the cassette no paper sensor away since it is connected with a harness. 7. Disconnect J205 from the sensor. 8. Remove the sensor.
Replacement
1. Swing the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette no paper sensor. 2. Reconnect J205 to the no paper sensor. 3. Position the sensor in the opening in the frame, and press the sensor into place until the hooks of the sensor snap into position. 4. Tack the extra length of the harness into the wiring channel of the cassette guide so that the harness does not interfere with the gears. 5. Reinstall the turn in chute (See page 676). 6. Reinstall the feed housing left (See page 668).
1 2 3 3
hc2m716F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing right (See page 670). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678).
Appendix G. 500-Sheet Paper Tray Option 685
5. Remove the three screws (1) securing the cassette guide assembly R (2) to the feeder assembly (Asm-Index: 20-1, page 697). 6. Using a at blade screwdriver, push the three hooks (3) at the bottom of the cassette guide assembly R, up and in, one by one, to release them from the frame of the feeder assembly. 7. Tilt the cassette guide, pulling its bottom edge from the inside of the frame. 8. Ensure that the three upper hooks of the cassette guide are released from the frame. 9. Remove the cassette guide from the feeder assembly.
Replacement
Reverse the Removal procedure.
hc3u717F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678). 5. Remove the cassette guide assembly left (See page 680).
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.
Feed Roll
Asm-Index: 21-11, page 700.
4 2 3
5
hc2m718F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the turn in chute (See page 676). 4. Remove the turn chute assembly aux. (See page 678).
5. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page 700) and the frame. 6. Remove the E-ring (3) securing the feed core (Asm-Index: 21-13, page 700) to the feed shaft assembly (4) (Asm-Index: 21-12, page 700). 7. Remove the feed core, the feed core spring (Asm-Index: 21-14, page 700), and the feed gear from the feed shaft assembly. 8. Rotate the feed shaft assembly until the rubber surface of the feed roll (5) faces to the front. Attention: Do not damage the cassette no paper actuator (Asm-Index: 20-26, page 697) and the rubber rolls. 9. Hold the feed shaft assembly away from the no paper actuator. 10. Press the hook of the feed roll to the front to remove it from the feed shaft.
Replacement
Attention: Do not damage the cassette no paper actuator and the rubber rolls. 1. Align the locating pin of the feed roll with the hole in the feed shaft. 2. Press the feed roll to the front to install it onto the shaft of the feed shaft. Attention: Ensure that the cams are located between the left and right pairs of the feed rolls. 3. Reinstall the feed core, the feed core spring, and the feed gear (Asm-Index: 21-15, page 700) from the feed shaft assembly (Asm-Index: 21-12, page 700). 4. Reinstall the E-ring that secures the feed core to the feed shaft assembly. 5. Rotate the feed shaft assembly manually and place the rubber surface of the feed roll upper position. 6. Reinstall the feed spring (Asm-Index: 21-17, page 700) on the feed gear and the frame. 7. Reinstall the turn chute assembly aux. (See page 678). 8. Reinstall the turn in chute (See page 676). 9. Reinstall the feed housing left (See page 668).
Appendix G. 500-Sheet Paper Tray Option 690
Feed Solenoid
Asm-Index: 21-18, page 700.
J204
hc2m720F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668).
3. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page 700) and the frame. 4. Disconnect J204 of the feed solenoid (3) from the feeder harness (Asm-Index: 20-22, page 697) on the cassette guide assembly L (Asm-Index: 20-16, page 697). 5. Remove the screw (4) securing the feed solenoid to the cassette guide assembly. 6. Remove the solenoid from the cassette guide.
Replacement
1. Place the feed solenoid in position and secure it using a screw (silver, 6mm). 2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly L. Attention: Route the harness so that it does not touch the gears. 3. Reinstall the feed spring between the feed gear and the feed solenoid. 4. Ensure that the armature of the feed solenoid xes the feed gear at the upper position, and releases at the lower position. 5. Rotate the feed shaft to place the rubber surface of the feed roll (Asm-Index: 21-11, page 700) up until the feed gear is released from the feed idler gear (Asm-Index: 21-22, page 700). 6. Reinstall the feed housing left (See page 668).
4 5 2
J206
3 2
hc2m721F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the feed housing right (See page 670). 4. Remove the turn in chute (See page 676).
Appendix G. 500-Sheet Paper Tray Option 693
5. Remove the turn chute assembly aux. (See page 678). 6. Remove the E-ring (1) at the right end of the turn roll assembly (2) (Asm-Index: 21-20, page 700). 7. Remove the right turn bearing (3) (Asm-Index: 21-21, page 700). 8. Disconnect J206 from the electromagnetic clutch aux (4). 9. Slide the turn roll assembly (Asm-Index: 21-20, page 700) to the left to remove the left turn bearing from the frame. 10. Remove the E-ring (5) securing the electromagnetic clutch to the turn roll assembly and remove the clutch from the turn roll.
Replacement
1. Place the electromagnetic clutch aux. to the turn roll assembly. 2. Reinstall the E-ring to secure the electromagnetic clutch to the turn roll assembly. 3. Insert the turn roll assembly from the left and insert the notch of the electromagnetic clutch to the arm of the frame. 4. Insert the left side turn bearing to the frame. 5. Install the right side turn bearing to the opening in the frame and secure the bearing using an E-ring. 6. Reconnect J206 to the electromagnetic clutch. Note: Route the harness so that it does not touch the gears. 7. Reinstall the turn chute assembly aux. (See page 678). 8. Reinstall the turn in chute (See page 676). 9. Reinstall the feed housing right (See page 670). 10. Reinstall the feed housing left (See page 668).
hc2m722F
Removal
1. Switch off printer power and unplug the power cord from the wall. 2. Remove the feed housing left (See page 668). 3. Remove the feed housing right (See page 670). 4. Remove the turn in chute (See page 676). 5. Remove the turn chute assembly aux. (See page 678). 6. Remove the electromagnetic clutch aux. (See page 693).
7. Remove the right side E-ring (1) securing the turn bearing (2) (Asm-Index: 21-21, page 700) to the turn roll assembly (3) and remove the right side turn bearing. 8. Remove the two left side E-rings (4) securing the turn bearing (5) to the turn roll assembly and remove the left side turn bearing. 9. Slide the turn roll assembly to the left and release its right end from the frame. 10. Slide the turn roll assembly to the right then backward and remove it from the frame.
Replacement
Reverse the Removal procedure.
hc2m704F
hc2m705F
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.707 .708 .708 .709 .710 .711 .716 .717 .717 .718 .718 .719 .720 .720 .721 .722 .722 .723 .724 .724 .725 .725 .726 .727 .728 .728 .729 703
Removal . . . . . . . . . . . Replacement. . . . . . . . . Near Empty Sensor . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Lower Position Sensor . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Size Sensor . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Harness . . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Chute . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Unit Assembly . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Right Hand Cover Open Switch Removal . . . . . . . . . . . Replacement. . . . . . . . . Exit Sensor . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roller Kit. . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Upper Limit Sensor . . . . . .
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.730 .730 .731 .731 .732 .733 .733 .734 .735 .735 .736 .737 .737 .738 .739 .740 .740 .741 .741 .742 .743 .743 .744 .745 .746 .746 .747 .748 .748 .750
Removal . . . . . . . . . . . Replacement. . . . . . . . . Paper Level Sensor . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Feed Roller . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Tray Set Sensor 1,2 . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Left Hand Cover Open Switch . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Motor . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . LVPS. . . . . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Rear Cover Kit . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Transport Roll Kit . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Flat Harness . . . . . . . . . . Removal . . . . . . . . . . . Replacement. . . . . . . . . Belt . . . . . . . . . . . . . .
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Removal . . . . . . . . Replacement. . . . . . Connector Kit . . . . . . Removal . . . . . . . . Replacement. . . . . . Parts Catalog . . . . . . . Assembly 40: 2000-Sheet Assembly 41: 2000-Sheet Assembly 42: 2000-Sheet
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Important Information
Note: When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches. One cord connects the option to the wall outlet, and the other connects the option to the printer. AC power is present on both machines even when both power switches are turned off.
26 PAPER JAM
There is a jam condition at the 2000-Sheet Input Option (High Capacity Feeder, HCF). This error is posted for several different conditions: v Paper never arrived at the HCF exit sensor actuator, located on the back door (chute) of the HCF. v Paper arrived at the the HCF exit sensor, but it never deactuated. v HCF tray (elevator) does not travel up or down correctly. (A 15 TRAY n NOT READ message will probably display rst and then turn into a 26 PAPER JAM message.) Notes: 1. When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches. One cord connects the option to the wall outlet, and the other connects the option to the printer. AC power is present on both machines even when both power switches are turned off. 2. If HCF option is installed directly beneath the printer, it is Tray 2. If a 500-sheet option is installed beneath the printer, it is Tray 2 and the HCF is Tray 3. In this MAP, generally the term Tray n is used. 3. It is normal for the HCF tray (elevator) to move after the printer power is turned on. It will move the tray up toward the top position where a sensor checks for a stack of paper. If no paper is detected, the tray moves all the way down (the position needed for paper loading). While the tray is moving, the operator panel may display a 15 2000-SHEET INPUT NOT READY message. 4. When the HCF tray is opened , the 15 2000-SHEET INPUT NOT READY message will display. The elevator should move down until it reaches its lowest position. After the tray is closed, the elevator should move up until the top of the stack of paper reaches the top position. (If there is no paper, it will move back down.) SUSPECT COMPONENTS 1. HCF pick problem (paper never leaves HCF tray, but paper loading is OK): v Feed Roller (Asm-Index: 41-14, page 776) v Feed Motor (Asm-Index: 42-28, page 778)
Appendix H. 2000-Sheet Input Drawer Option 711
v Flat Harness (Asm-Index: 42-29, page 778) 2. HCF transport problem (paper gets picked and starts to leave the tray, but does not continue into paper path): v Transport Motor (Asm-Index: 42-21, page 778) v Transport Belt (Asm-Index: 42-22, page 778) v Transport Gear (Asm-Index: 42-23, page 778) v Transport Roll (Asm-Index: 42-7, page 778) - test with D68 HCF MOTOR (HCF Transport Motor) on page 291 v Flat Harness (Asm-Index: 42-7, page 778) v Paper Chute (Asm-Index: 42-5, page 778) 3. HCF elevator problem: v Test with D44 HCF UP (Tray Lifts) on page 273 & D45 HCF DOWN (Tray Lowers) on page 275 v Lift up motor (Asm-Index: 41-10, page 776) v Lower position sensor (Asm-Index: 41-12, page 776) v Upper limit sensor (Asm-Index: 42-11, page 778), test with D21 SENSOR TEST on page 261 v Paper level sensor (Asm-Index: 42-2, page 778) 4. Sensor Problems that cause false 26 errors after power is turned on: v HCF exit sensor (42-10)- test with D21 SENSOR TEST on page 261 v Tray set #2 sensor (42-19) - 15 message will occur rst - test with D21 SENSOR TEST on page 261 5. Sensor Problems that cause 26 during printing from HCF: v HCF exit sensor actuator (Asm-Index: 42-5, page 778) v HCF exit sensor (42-10) - test with D21 SENSOR TEST on page 261 v No paper sensor (Asm-Index: 42-28, page 778) - test with D21 SENSOR TEST on page 261
Appendix H. 2000-Sheet Input Drawer Option 712
v Paper level sensor (Asm-Index: 42-2, page 778) Note: The HCF near empty sensor is not used 6. General FRUs for 26 Jam (valid in all of the lists above) v HCF LVPS (Asm-Index: 42-25, page 778) v Cables (check all connections at HCF LVPS) v HCF option v MCU
Table 96. 26 PAPER JAM
Step Actions and Questions Switch on the printer power and the HCF power. Wait until the printer is ready or an error displays. Is there an error? Wait 2 minutes to see if the 15 error turns into a 26 PAPER JAM. 2. Does a 26 PAPER JAM display? Open the rear door of the HCF. Is there any paper or paper scraps in the path? 3. Remove the paper. Open and close the top cover to reset the error. Go to step 4. Yes No
1.
If the initial error is Go to step 4 26, go to step 3. If the initial error is 15, go to step 2. Go to step 4 For other errors, go to Chapter 1. Getting Started on page 25. False 26 errors. Go to Suspect Components list 4, then 3 and 6.
5.
6.
8.
Run D68 (see D68 HCF MOTOR (HCF Transport Motor) on page 291). You Go to step 9 will have to override the HCF rear cover switches to watch the transport roll move. Does the Transport Roll move? You have a problem caused by one of the following: v HCF exit actuator (Asm-Index: 42-5, page 778)
9.
v HCF exit sensor (42-10) - test with D21 SENSOR TEST on page 261 v Paper path obstruction
10.
End of Diagnostic
Wiring Diagram
LVPS
LIFT UP MOTOR CONTROL P/J:XS1 10 9 1 2 5 6 3 4 7 8 P/J:XS2 12 11 25 26 P/J:XS3 P/J:XS4 RXD 14 1 TXD 16 2 SG 12 3 SG 13 4 FEEDER CHECK 9 5 3 4 5 FEED MOTOR CONTROL 1 2 6 7 8 22 23 24 9 10 13 14 15 TRANSPORT MOTOR CONTROL 18 19 20 21 16 17 27 28 MAIN SWITCH
GND GND DC21 DC22 DC22 SWHD SG SWPL(TTL) SG SWPSZ(TTL) FG
CPU
P/J:M1 (+) (-) P/J:S2 1 3 P/J:S1 1 3 P/J:S3 1 3 P/J:S7 2 1 P/J:S11 1 3 P/J:P1 3 2 1 5 4 P/J:P2 1 2 3 P/J:S10 1 2 3 P/J:S6 1 2 P/J:S8 1 2 3 P/J:M2 1 2 3 4 P/J:S9 1 2 P/J:S12 1 2
SIZE SENSOR
DC21 SWHU1 SWHU1 SWHU2 +5VDC LSPE(TTL) SG DC11 DC12 +5VDC ENCOD(TTL) SG +5VDC LSPL(TTL) SG SWCPR(TTL) SG +5VDC LSPEX(TTL) SG SM1 SM2 SM3 SM4 SWDO1(TTL) SG SWDO1(TTL) SWDO(TTL)
NO PAPER SENSOR
FEED MOTOR
ENCODER
SG
SENSOR
TRANSPORT MOTOR
LEFT HAND COVER OPEN SWITCH RIGHT HAND COVER OPEN SWITCH
AC to DC
SERVICE CONNECT
AC INLET
hc2m089F
This is an internal wiring of the FEED ROLLER KIT, therefore the P/J No. and Pin No. are omitted.
[1]
hc2m072F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Remove the Paper Cassette from the Base Engine or Option Tray. Remove the two screws (1) that lock the HCF to the Base Engine.
5. Lift the Base Engine to separate the Base Engine and the HCF. Remove the HCF.
Replacement
Attention: In the step below, match the HCF positioning boss with the Base Engine positioning boss. Gently place the main unit on the HCF; make sure it goes on straight. 1. Lift the Base Engine and install it on the HCF. 2. Lock the Base Engine and the HCF with the two screws. 3. Install the paper cassette, if Base Engine or Option Tray is installed.
Foot
Asm-Index: 40-3, page 774.
hc2m024F
2 2 1
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the four screws (1) that lock the Foot (2). Remove the Foot.
Replacement
Reverse the Removal procedure.
1 2
hc2m023F
1
[3] [4]
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Pull out the HCF Tray Assembly. 4. Disconnect the P/J:XS1 (See 1 in the gure). Attention: In the next step, carefully sqeeze the release hooks on the clamp from the backside. The hooks break easily. 5. Remove the harness clamp (See 2 in the gure). 6. Remove the two screws (1) securing the HCF Tray Assembly (2). 7. Remove the hooks (See 3 in the gure) on the front side of the slide rails. (The hooks lock the HCF Tray Assembly.) Attention: When you remove the HCF Tray Assembly in the step below, support the Tray (rear) so that it will not fall. 8. Remove the hooks (See 4 in the gure) on the rear side of the slide rails. (The hooks lock the HCF Tray Assembly.)
Replacement
1. Install the rear hooks on the HCF Tray Assembly. 2. Install the front hooks on the HCF Tray Assembly. 3. Lock the HCF Tray Assembly with the two screws . 4. Install the harness clamp. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 5. Connect the P/J:XS1. 6. Insert the HCF Tray Assembly into the HCF.
Side Plate
Asm-Index: 41-3 and 41-13, page 776.
1 1
hc2m025F
Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Turn the keys that lock the Side Plates (1). Remove the Side Plates.
Replacement
Reverse the Removal procedure.
Front Cover
Asm-Index: 41-7, page 776.
hc2m026F
Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the four screws (1) that lock the Front Cover (2). Remove the Front Cover.
Appendix H. 2000-Sheet Input Drawer Option 725
Replacement
Attention: When you install the Front Cover in the step below, make sure that all the hooks are in place. 1. Install the Front Cover. 2. Lock the Front Cover with the four screws. 3. Insert the HCF Tray Assembly into the HCF.
Lift Up Motor
Asm-Index: 41-10, page 776.
1
[2] Black + Red P/J:M1-(+) P/J:M1-(-) [1]
hc2m027F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Front Cover (See page 725).
5. Disconnect the P/J :M1. Attention: When you remove the Lift Up Motor in the steps below, place an object or your hand on the Bottom Plate to prevent it from springing up. 6. Remove the two screws that lock the Lift Up Motor. You can also remove the motor by just loosening them. 7. Remove the E-ring. 8. Remove the Lift Up Motor.
Replacement
1. Install the Lift Up Motor. 2. Install the E-ring. Attention: When you lock the Lift Up Motor in the step below, the tube washer should not overlap the positioning post. (See 1 in the gure.) 3. Lock the Lift Up Motor with the two screws. Attention: In the step below, check the cable color when connecting the P/J. If the P/J is not connected properly, the system malfunctions or may be damaged. (See 2 in the gure). When you connect the P/J in the step below, make sure that the harness or other components are not touching the motors rotating components.If they come in contact with the rotating components, they will be damaged. 4. Connect the P/J :M1. 5. Install the Front Cover (See page 725). 6. Insert the HCF Tray Assembly into HCF.
Bottom Plate
Asm-Index: 41-2, page 776.
[2] [1]
1
[3]
1
hc2m046F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Plates (See page 723).
5. Remove the locks (see 1 in the gure) on the Bottom Plate (1) (use a screwdriver if necessary). 6. Lift the back side of the Bottom Plate, remove the Bottom Plate (See 2 in the gure).
Replacement
Attention: When you install the Bottom Plate in the step below, make sure that the rear roller in the Lift Up mechanism has been properly installed on the roller guide of the Bottom Plate (See 3 in the gure). 1. Install the Bottom Plate. 2. Lock the Bottom Plate (use a screwdriver if necessary). 3. Install the Side Plates (See page 723). 4. Insert the HCF Tray Assembly into the HCF.
hc2m028F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Pull out the HCF Tray Assembly.
Appendix H. 2000-Sheet Input Drawer Option 731
4. Remove the Front Cover (See page 725). 5. Remove the Near Empty Sensor. 6. Disconnect the P/J:S1.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S1. Attention: In the step below, install the Near Empty Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Near Empty Sensor (1). 3. Install the Front Cover (See page 725). 4. Insert the HCF Tray Assembly.
hc2m029F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Panels (See page 723).
Appendix H. 2000-Sheet Input Drawer Option 733
5. Remove the Bottom Plate (See page 729). 6. Remove the Lower Position Sensor (1). 7. Disconnect the P/J:S2.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S2. Attention: In the step below, install the Lower Position Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Lower Position Sensor. 3. Install the Bottom Plate (See page 729). 4. Install the Side Plates (See page 723). 5. Insert the HCF Tray Assembly into the HCF.
Size Sensor
Asm-Index: 41-15, page 776.
hc2m073F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Remove the Side Plates (See page 723).
Appendix H. 2000-Sheet Input Drawer Option 735
5. Remove the Bottom Plates (See page 729). 6. Remove the Size Sensor (1). 7. Disconnect the P/J:S3.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S3. Attention: In the step below, install the Size Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Size Sensor. 3. Install the Bottom Plate (See page 729). 4. Install the Side Plates (See page 723). 5. Insert the HCF Tray Assembly into the HCF.
Harness
Asm-Index: 41-16, page 776.
[2] [1]
[3]
[4]
[7]
Orange [5]
Black
+
Brown
Red
hc2m078F
Removal
1. 2. 3. 4. 5. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Pull out the HCF Tray Assembly. Disconnect the P/J:XS1 (See 1 in the gure). Remove the Front Cover (See page 725).
6. Remove the Bottom Plate (See page 729). 7. Remove the Holder (See 2 and 3 in the gure). 8. Remove the cable clamp.
Appendix H. 2000-Sheet Input Drawer Option 737
9. Disconnect the P/Js that are connected to the following: Near Empty Sensor, Size Sensor , Lower Position Sensor and Lift Up Motor. 10. Remove the Harness (1).
Replacement
1. Install the Harness. Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 2. Connect the P/Js to the following: Near Empty Sensor, Size Sensor, Lower Position Sensor and Lift Up Motor. 3. Install the cable clamp. 4. Install the Holder. 5. Install the Bottom Plate (See page 729). 6. Install the Front Cover (See page 725). Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 7. Connect the P/J:XS1. 8. Insert the HCF Tray Assembly into the HCF.
Paper Chute
Asm-Index: 42-5, page 778.
[1]
hc2m032F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Rear Cover Kit (1) from the HCF (See page 764). 4. Remove the Paper Chute (2) from the Rear Cover Kit.
Replacement
Attention: When you install the Paper Chute in the step below, make sure that the four springs are installed properly, otherwise the system will malfunction (See 1 in the gure). 1. Install the Paper Chute to the Rear Cover Kit. 2. Install the Rear Cover Kit to the HCF (See page 764).
1
hc2m045F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.
Appendix H. 2000-Sheet Input Drawer Option 741
3. Remove the Rear Cover Kit from the HCF (See page 764). 4. Roll out the HCF Tray Assembly from the HCF. 5. Disconnect the P/J:XS2 from LVPS. Attention: When you remove the screws in the step below, support the Transport Unit Assembly rmly with your hand so that it will not fall. 6. Remove the two screws (1) securing the Transport Unit Assembly (2). 7. Remove the Transport Unit Assembly.
Replacement
1. Install the Transport Unit Assembly. 2. Secure the Transport Unit Assembly with the two screws. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 3. Connect the P/J:XS2 to LVPS. 4. Insert the HCF Tray Assembly into the HCF. 5. Install the Rear Cover Kit to the HCF (See page 764).
1
hc2m041F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.
Appendix H. 2000-Sheet Input Drawer Option 743
3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Right Hand Cover Open Switch (1). 5. Disconnect the P/J:S12.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S12. Attention: In the step below, install the Right Hand Cover Open Switch in the correct direction, otherwise the switch pins may be damaged. 2. Install the Right Hand Cover Open Switch. 3. Install the Transport Unit Assembly (See page 741).
Exit Sensor
Asm-Index: 42-10, page 778.
hc2m035F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Disconnect the P/J:S8. 5. Remove the Exit Sensor (1).
Replacement
1. Install the Exit Sensor. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:S8. 3. Install the Transport Unit Assembly (See page 741).
2 1 3
[3]
5
hc2m030F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).
4. 5. 6. 7. 8.
Disconnect the P/J:P1 and P/J:P2 connected to the Feed Roller Kit Harness (1). Remove the harness clamp securing the Feed Roller Kit Harness . Remove the two Feed Roller Kit Springs (2). Remove the hooks (3) (See 1 in the gure) securing the Feed Roller Kit (4). Remove the Right Hand Feed Roller Bracket (5) and the Left Hand Feed Roller Bracket (6) (See 2 in the gure)that lock the Feed Roller Kit. 9. Remove the Feed Roller Kit.
Replacement
Attention: In the step below, check that the Feed Roller Kit properly pushes the Paper Level Sensor Actuator (See 3 in the gure). 1. Install the Feed Roller Kit. 2. Fix the Feed Roller Kit on the Right Hand Feed Roller Bracket and Left Hand Feed Roller Bracket and attach it to the frame in the Transport Unit Assembly. 3. Secure the Feed Roller Kit using the hooks. 4. Install the two Feed Roller Kit Springs. 5. Secure the Feed Roller Kit Harness with the harness clamp. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 6. Connect the P/J:P1 and P/J:P2. 7. Install the Transport Unit Assembly (See page 741).
1
hc2m036F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Feed Roller Kit (See page 747). 5. Remove the Upper Limit Sensor (1).
Appendix H. 2000-Sheet Input Drawer Option 750
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S11. Attention: In the step below, install the Upper Limit Sensor to the correct direction, otherwise the sensor pins may be damaged. 2. Install the Upper Limit Sensor. 3. Install the Feed Roller Kit (See page 747). 4. Install the Transport Unit Assembly (See page 741).
hc2m037F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Feed Roller Kit (See page 747). 5. Disconnect the P/J:10.
Appendix H. 2000-Sheet Input Drawer Option 752
Replacement
1. Install the Paper Level Sensor. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:10. 3. Install the Feed Roller Kit (See page 747). 4. Install the Transport Unit Assembly (See page 741).
Feed Roller
Asm-Index: 42-14, page 778.
1
hc2m038F
Removal
1. 2. 3. 4. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. Remove paper from the HCF Tray. Open the Rear Cover Kit. Remove the Feed Roller (1).
Appendix H. 2000-Sheet Input Drawer Option 754
Replacement
Reverse the Removal procedure.
hc2m039F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Tray Set Sensors 1 (1) and 2 (2).
Note: Label the wires before removing them in the next step. 5. Disconnect the P/J:S6 and P/J :S7.
Replacement
Attention: In the step below, connect the P/Js as labeled, otherwise the system malfunctions. 1. Connect the P/J:S6 and P/J :S7. Attention: In the step below, install the Tray Set Sensors 1 and 2 in the correct direction, otherwise the sensor pins may be damaged. 2. Install the Tray Set Sensors 1 and 2. 3. Install the Transport Unit Assembly (See page 741).
hc2m040F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray.
3. Remove the Transport Unit Assembly (See page 741). 4. Remove the Left Hand Cover Open Switch (1). 5. Disconnect the P/J:S9.
Replacement
Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system malfunctions. 1. Connect the P/J:S9. Attention: In the step below, install the Left Hand Cover Open Switch in the correct direction, otherwise the switch pins may be damaged. 2. Install the Left Hand Cover Open Switch. 3. Install the Transport Unit Assembly (See page 741).
Transport Motor
Asm-Index: 42-21, page 778.
1
hc2m042F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).
4. Disconnect the P/J:M2. 5. Remove the two screws (1) securing the Transport Motor (2). 6. Remove the Transport Motor.
Replacement
1. Secure the Transport Motor with the two screws . Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:M2. 3. Install the Transport Unit Assembly (See page 741).
LVPS
Asm-Index: 42-25, page 778.
1
hc2m043F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the HCF Tray Assembly (See page 721).
Appendix H. 2000-Sheet Input Drawer Option 762
4. 5. 6. 7.
Disconnect the P/J:XS1, XS2, XS3. Remove the screw (1) securing the ground wire coming from LVPS (2). Remove the four screws (3) securing the LVPS to the HCF. Remove LVPS.
Replacement
1. Secure LVPS to HCF with the four screws . 2. Secure LVPS ground wire with the screw. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 3. Connect the P/J:XS1, XS2, XS3. 4. Install the HCF Tray Assembly (See page 721).
hc2m031F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Open the Rear Cover Kit (1). Note: In the step below, open the Rear Cover Kit halfway for easy removal. 4. Remove the Screw (2) holding the strap. 5. Remove the Rear Cover Kit.
Replacement
Reverse the Removal procedure.
3
[1]
5 4
hc2m033F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741). 4. 5. 6. 7. 8. Remove Remove Remove Remove Remove the the the the the two E-rings (1). Gear (2). Left Hand Lock (3). Right Hand Lock (4). Transport Roll (5).
Replacement
1. Install the Transport Roll. 2. Install the Right Hand Lock. 3. Install the Left Hand Lock. Attention: In the step below, install the Gear so that the belt guard (See 1 in the gure) is to the outside. 4. Install the Gear. 5. Install the ve E-rings. 6. Install the Transport Unit Assembly (See page 741).
Flat Harness
Asm-Index: 42-29, page 778.
hc2m044F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).
4. Disconnect all P/Js connected to the Flat Harness. 5. Remove all harness clamps securing the Flat Harness. 6. Disconnect the Flat Harness (1).
Replacement
1. Connect the Flat Harness. 2. Secure Flat Harness with the harness clamps. Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system will malfanction. 3. Connect the P/Js. 4. Install the Transport Unit Assembly (See page 741).
Belt
Asm-Index: 42-22, page 778.
hc2m079F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the Transport Unit Assembly (See page 741).
Appendix H. 2000-Sheet Input Drawer Option 770
4. Remove the Transport Motor (See page 760). 5. Remove the Belt (1).
Replacement
Reverse the Removal procedure.
Connector Kit
Asm-Index: 42-32, page 778.
[1] [2]
1 2
hc2m080F
Removal
1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall. 2. Remove paper from the HCF Tray. 3. Remove the HCF from the Base Engine (See page 717). 4. Disconnect the P/J:XS3 (See 1 in the gure). 5. Remove the two screws (1) securing the Connector Kit (2). 6. Disconnect the Connector Kit.
Replacement
1. Connect the Connector Kit. Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may be damaged. 2. Connect the P/J:XS3. 3. Secure the Connector Kit with the two screws. 4. Install the Base Engine.
1 (with 1A-18)
10 15 10 2. (PL42.1)
A
1A (PL41.1)
A
14
11
B
13 12 13 17 16 4 18 (with 16,17) 3 12 4 11
19 (with 4,5)
5 4 3 4
hc2m020F
19 (with 4,5)
1 (with 2-18) 13 2
4 17 16 5 15 12 14 14 14 6
B
17 18 7
B
14 18 5
11 10 9
C C
9 8
hc2m021F
3
26 (with 2,4,5,33)
A
30
B
20 29
B
6
13 19 18 12 36 9 11 14 17 15 16
hc2m022F
C
28 (with 14-17,36)
Glossary
The following terms are dened as they are used in this publication. If you do not nd the term you need, see the IBM Dictionary of Computing, New York, McGraw-Hill, 1994, or the IBM Dictionary of Printing. The following cross-references are used in this glossary: v Contrast with refers to a term that has an opposite meaning. v See refers to a preferred term with the same meaning. v See also refers to related terms.
A
A4-size paper. Paper that is 210 by 297 mm (8.3 x 11.7 in.). ac. Alternating current asm. Assembly attention notice. An attention warns of possible of damage to a program, device, system, or data. Attention notices are located throughout this publication. Attention notices are not translated. aux. Auxiliary
B
B5-size ISO paper.. Paper that is 176 mm by 250 mm (6.93 in. by 9.84 in.). B5-size JIS paper. Paper that is 182 mm by 257 mm (7.17 in. by 10.12 in.). BCR. Bias charge roller. BTR. Bias transfer roller.
781
C
caution notice. A notice that calls attention to a condition that is potentially dangerous to people. CCW. Counterclockwise charge. The negative voltage that the HVPS applies to the surface of the drum. CM. Charge metering. continuity. A resistance reading of approximately zero (0) ohms. CR. Signal name for the charge voltage. CRU. Customer replaceable unit, such as the EP cartridge. CW. Clockwise
D
danger notice. A notice used to call attention to a condition that is potentially deadly or extremely dangerous. DB. Signal name for the developer bias voltage. dc. Direct current. default. An adjustment or setting that is set at the time of equipment manufacture. detack. Separating the toned sheet of paper from the surface of the drum after imaging. develop. The process when toner adheres to the latent image on the drum. developed image. The visible image on the drum after going through the development process. DPI. Dots per inch. The number of dots per inch printed by a laser printer. Each dot is either on or off, printed or not printed. See also (PPI). DRAM. Dynamic random-access memory.
Glossary 782
drum. The electrophotographic receptor. DTS. Signal name for the deteck saw voltage. duplex. Printing on both sides of a single sheet of paper.
E
EP. Electrophotographic. EP cartridge. The electrophotographic cartridge; sometimes referred to as the print cartridge, the toner cartridge, or as the CRU. error code. A unique set of letters and numbers that the printer displays to indicate that a problem exists in a specic area of the printer. ESD. Electrostatic discharge, which if discharged into the circuitry of an integrated circuit, can damage the circuit. exposure. The action of the laser beam striking and discharging select areas of the electrically charged surface of the drum.
F
FG. Frame ground. FU. Face-up. This abbreviation is used in some display messages. fuser. The printer subsystem that uses heat and pressure to permanently adhere, or fuse, a transferred toner image to a sheet of paper.
G
ground. Electrical ground.
Glossary 783
H
harness. A bundle of wires that form a single unit and are generally terminated with connectors at both ends. HCF. High capacity feeder, or 2000-Sheet Input Drawer HCI. High capacity input high. A signal voltage that is equal to or almost equal to the base voltage; such as +5 V dc or +24 V dc. See also low. HVPS. High voltage power supply.
I
image density. The relative darkness of the latent image on a sheet of paper. image development. Toner turning the latent image into a visible image. See also develop. image fusing. Using heat and pressure to permanently adhere a toned image to a sheet of paper. image transfer. Moving the developed image from the surface of the drum to the surface of a sheet of paper. interlock. Interlock switch. Used as a safety measure to remove voltage from circuits whenever a printer cover or the like is opened.
J
J. Jack. A female electrical connector. See also P and P/J.
K
KB. Kilobyte. 1 024 bytes. Kb. Kilobit. 1 024 bits.
Glossary 784
L
laser. Refers to the laser diode or to the laser beam. laser diode. Generates the laser beam that is used in the laser unit. laser beam path. The path that the laser beam takes, through lenses and mirrors, from the laser diode to the surface of the drum. latent image. The visible, electrical image remaining on the surface of the drum after exposure. LCD. Liquid crystal diode. LED. Light emitting diode. LEF. Long edge feed. legal-size paper. Paper that is 216 mm x 356 mm (8.5 in. x 14.0 in.). letter-size paper. Paper that is 216 mm x 279 mm (8.5 in. x 11.0 in.). low. A signal voltage that is signicantly lower than the base voltage. See also high. LVPS. Low voltage power supply.
M
MB. Megabyte. 1 024 000 bytes. Mb. Megabit. 1 024 000 bits. MBF. Multi-bypass lter. MCU. Machine control unit.
Glossary 785
N
NC. No connection. NOP. No paper. NVRAM. Non-volatile random access memory.
P
P. Plug A Male electrical connector.See also J and P/J. P/J. Plug/jack. A connected male (plug) and a female (jack). See also J and P. pel. See pixel. pixel (pel). (1) The smallest distinct element of a raster image or an image displayed on a monitor. (2) The elementary graphical cell that constitutes an image. (3) An element of a raster pattern or a point where a toned area on a photoconductor can appear. Pixels per inch (ppi). The number of pixels per linear inch. Unlike dots, which are bilevel entities, pixels can hold multiple levels of information. See also dots per inch. point. A unit of measurement for describing type sizes. There are 12 points to a pica; about 72 points to an inch. PPI. Pixels per inch. See also dots per inch (DPI). PPM. Pages per minute. print surface. The side of a sheet of paper that receives the printed image.
R
RTN. Return.
Glossary 786
S
SEF. Short edge feed. sensor. A device used to monitor a function or an operation, such as paper travel along the paper path. SG. Signal ground. signal name. A name given to a wire indicating the purpose of the wire and/or the voltage carried by that wire. SIMM. Single inline memory module. simplex. Generally means printing only on one side of a sheet of paper. See also duplex. SOS. Start of scan.
T
toggle. To switch between two states, such as on and off or up and down. toner. The dry ink that is used to create the visible image. Toner is stored in the EP cartridge. TR. Signal name for transfer current. transfer. Moving the toner image (developed image) from the surface of the drum to the surface of a sheet of paper.
Glossary 787
Index A
asm. locations duplex 362 env. feeder 362 printer 362 assembly locations 547
D
DANGER notice 6 defects, print quality detergent 588 diagnostic quick path diagnostics See getting started test prints, running paper path 251 disposal of materials documents, obtaining 34 28 25
603
H
home page, Printing Systems Company 603
B
books, obtaining from web 603
8 from web
I
603 information, gathering 26 instructions, safety inspection 12 intermittent problems or errors 133
C
cable ESD (electrostatic discharge) 20 cable, ESD (electrostatic discharge) 20 CAUTION notice 7 cleaners and lubricants 588 clutch locations env. feeder 364 printer 364 code updates, obtaining from web 603 commonly used fasteners 588 parts 587 completing your task 36 components, electrical, location 364 connector locations printer 367 Copyright IBM Corp. 1998
E
electrical system safety 8 error codes and messages 000099 30, 31, 32 ESD procedures 20 30
L
laser safety 10 locations asms. duplex 362 env. feed 362 printer 362 clutches env. feeder 364 printer 364 connectors printer 367 electrical components 364 clutches, solenoids 364 miscellaneous 390 sensors 384
F
fasteners, common 588 fault isolation See diagnostic quick path 28 xes, obtaining from web 603
G
gathering information getting started 25 26
788
locations (continued) mechanical duplex 391 printer 390 mechanical components 390 PCBs duplex 380 env. feeder 380 printer 380 quick path 361 sensors duplex 384, 386 env. feeder 384, 386 printer 384, 386 solenoids env. feeder 364 printer 364 switches duplex 384, 386 env. feeder 384, 386 printer 384, 386 lubricants and cleaners 588
29
N
Network Interface Card 541 NIC 541 notices electrostatic discharge (ESD) safety CAUTION 7 DANGER 6 description 6 safety precautions 8 disposal of materials 8 electrical safety 8 laser safety 10 ozone safety 11 toner safety 11 trademarks 22 20
O
oil 588 ozone safety 11
M
manuals, obtaining from web 603 marking actions as completed, safety inspection 13 mat, ESD 20 mechanical, locations 390 mechanical locations duplex 391 env. feeder 391 printer 390
parts catalog (continued) how to use (continued) grid 546 part number 546 units 547 parts catalog, how to use asm./index 546 parts location 547 PCB locations duplex 380 env. feeder 380 printer 380 print, paper path test 251 print quality defects 34 print quality problems 33 printer safety inspection 13 printer safety inspection 13 Printing Systems Company web page 603 problems intermittent 133 random 133 program xes, obtaining from web 603
P
paper path 251 test print 251 parts, common 587 parts catalog assembly locations 548 how to use description 547
Q
quick path, locations 361
R
random problems or errors 133 reference items, safety inspection routine tasks 35 13
Index 789
S
safety inspection 12 instructions 12 marking actions as completed printer 13 printer safety inspection 13 reference items 13 safety notices CAUTION 7 DANGER 6 description 6 safety precautions 8 disposal of materials 8 electrical safety 8 laser safety 10 ozone safety 11 toner safety 11 sensor locations duplex 384, 386 env. feeder 384, 386 printer 384, 386 sensors locations 384 SIMM 539 soap 588 solenoid locations env. feeder 364 printer 364 START of Call See getting started 25 13
status messages 239 switch locations duplex 384, 386 env. feeder 384, 386 printer 384, 386
T
test print, paper path 251 test prints, running 251 toner safety 11 trademarks 22 troubleshooting See getting started 25
U
updates (code), obtaining from web 603 utilities, obtaining from web 603
W
web page, Printing Systems Company 603 wrist band, ESD 20
Index 790
Printed in the United States of America on recycled paper containing 10% recovered post-consumer ber.
G544-5514-01