infoprint 20 svc guide 2

IBM InfoPrint 20

Service Guide

Document Number: G544-5514-01

IBM

NoteBefore using this information and the product it supports, be sure to read the generalinformation in “Notices” on page 5.

Second Edition (August 1998)

This edition applies to Release 2.0 of the IBM InfoPrint 20 Service Guide, G544-5514-01.

The following paragraph does not apply to any country where such provisions are inconsistent with local law.

INTERNATIONAL BUSINESS MACHINES CORPORATION PROVIDES THIS PUBLICATION “AS IS” WITHOUT WARRANTY OFANY KIND, EITHER EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO THE IMPLIED WARRANTIES OFMERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not allow disclaimer of express or impliedwarranties in certain transactions; therefore, this statement may not apply to you.

Order publications through your IBM representative, your IBM Printing Systems Company printing specialist, or the IBM branchoffice serving your locality. Publications are not stocked at the address given below.

IBM Printing Systems Company home page:http://www.printers.ibm.com

IBM and the IBM Printing Systems Company welcome your comments. Either fax your comments to 1-303-924-6873, e-mailthem to [email protected], or mail them to:

Department H7FE, Building 003G

The IBM Printing Systems Company

Information Development

P.O. Box 1900

Boulder, CO 80301-9191, U.S.A.

When you send information to IBM, you grant IBM a non-exclusive right to use or distribute the information in any way it believesappropriate without incurring any obligation to you. Copyright International Business Machines Corporation 1998. All rightsreserved. Note to U.S. Government Users—Documentation related to restricted rights—use, duplication or disclosure is subjectto restrictions set forth in GSA ADP Schedule Contract with IBM Corporation.

© Copyright International Business Machines Corporation 1998. All rights reserved.Note to U.S. Government Users — Documentation related to restricted rights — Use, duplication or disclosure is subject torestrictions set forth in GSA ADP Schedule Contract with IBM Corp.

Master Table of Contents“Notices” on page 5

“About This Book” on page 23

“Chapter 1. Getting Started” on page 25

“Chapter 2. Diagnosing Problems” on page 37

“Chapter 3. Diagnostic Tools” on page 247

“Chapter 4. Circuit Diagrams” on page 307

“Chapter 5. Locations” on page 360

“Chapter 6. Removal Procedures, Adjustments” on page 394

“Chapter 7. Preventive Maintenance and Usage Kit” on page 543

“Chapter 8. Parts Catalog” on page 544

“Appendix A. Features” on page 589

“Appendix B. Supplies” on page 591

“Appendix C. Media Specifications” on page 593

“Appendix D. Technical Support” on page 602

“Appendix E. Duplex Unit Option” on page 604

“Appendix F. Envelope Tray Option” on page 658

© Copyright IBM Corp. 1998 3

“Appendix G. 500-Sheet Paper Tray Option” on page 661

“Appendix H. 2000-Sheet Input Drawer Option” on page 703

“Index” on page 788

Master Table of Contents 4

NoticesReferences in this publication to IBM products, programs or services do not imply that IBM intends to makethese available in all countries in which IBM operates. Any reference to an IBM licensed product, program, orservice is not intended to state or imply that only IBM’s product, program, or service may be used. Anyfunctionally equivalent product, program, or service that does not infringe any of IBM’s intellectual propertyrights may be used instead of the IBM product. Evaluation and verification of operation in conjunction withother products, except those expressly designated by IBM, is the user’s responsibility.

Any performance data contained in this document was obtained in a controlled environment based on the useof specific data. The results that may be obtained in other operating environments may vary significantly.Users of this document should verify the applicable data in their specific environment. Therefore, such datadoes not constitute a performance guarantee or warranty.

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


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

Danger NoticesThe word Danger indicates the presence of a hazard that has the potential of causing death or seriouspersonal injury.

Danger notices are numbered <1-10>, <1-11>, and so forth where they appear in the text of this manual. Usethe notice number to locate the national language translation of that notice in the IBM InfoPrint 20: SafetyInstructions.

Example danger notice:

Notices 6

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

Caution notices are numbered <2-20>, <2-21>, and so forth where they appear in the text of this manual. Usethe notice number to locate the national language translation of that notice in the IBM InfoPrint 20: SafetyInstructions.

Example caution notice:

Notices 7

Safety Precautions

Disposal of Materials

Electrical SafetyThis printer is inspected and listed by recognized national testing laboratories, such as UnderwritersLaboratories, Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of aproduct by a national testing laboratory indicates that the product is designed and manufactured in accordancewith national requirements intended to minimize safety hazards. IBM equipment meets a very high standard ofsafety in design and manufacture. Remember, however, that this product operates under conditions of highelectrical potentials and heat generation, both of which are functionally necessary.

Because the paper and toner used in the printer can burn, take normal precautions to prevent fire. Theseprecautions include common-sense measures, such as keeping potentially combustible materials (for example,curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limiting unattended

Notices 8

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

Notices 9

Laser SafetyThis printer complies with the performance standards set the by U.S. Food and Drug Administration for aClass 1 Laser Product. This means that the printer belongs to a class of laser products that does not producehazardous laser radiation in a customer access area. This classification was accomplished by providing thenecessary protective housing and scanning safeguards to ensure that laser radiation is inaccessible or withinClass 1 limits.

There are various tool-operated machine covers that should be moved, removed, or replaced only by trainedservice personnel. There are no operator controls or adjustments associated with the laser.

No operator maintenance is required to keep the product in compliance as a Class 1 Laser Product. Noadjustments that affect laser operation or power are accessible to the operator. See the IBM InfoPrint 20:Safety Instructions for national language translations regarding laser safety.

Notices 10

Ozone SafetyAn infinitesimal amount of ozone gas (O3) is generated during corona discharge from the transfer chargeroller. The ozone gas is emitted only when the printer is operating.

This printer meets the ozone emission reference value set by Underwriters Laboratory (UL) at the time it isshipped from the factory.

Toner SafetyToner is a non-poisonous substance composer of minute, plastic components. If toner adheres to your skin orto your clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hotwater, the toner will gel and become difficult to remove.

As toner easily breaks down vinyl materials, avoid letting toner come into contact with vinyl.

Notices 11

Safety InspectionSee “Danger Notices” on page 6 and “Caution Notices” on page 7 for an explanation of these notices.

InstructionsPerform a safety inspection before performing any of the following tasks:v Accepting a machine for a service agreementv Providing per-call servicev Relocating a machinev Reviewing changes or attachments on any IBM machine that is leased, on service agreement, or on

per-call service

Correct unsafe conditions before you continue.

Possible safety hazards are:v Electrical—An electrically charged frame, or exposed wires or connections, can cause serious electrical

shock.v Mechanical—A missing safety cover or shield is hazardous. Moving parts, such as gears, shaft, and pulleys

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

Notices 12

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

Printer Safety Inspection1. Switch off printer power and unplug the power cord from the wall.2. Perform the “Power-Receptacle Safety-Check” on page 17.

3. Ensure that all cables are disconnected from the printer.4. Ensure that the correct power cord is used.5. Inspect the power cord for wear or damage.6. Ensure that the machine is steady.7. Remove all covers and access panels (see “Chapter 6. Removal Procedures, Adjustments” on page 394).

8. Inspect the covers and access panels for damage.9. Ensure that all warning labels are in place.

10. If you are placing this printer on a service contract with IBM, check for changes not made by IBM. If youfind changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBMbranch office. Complete the form and return it to the branch office.

11. Ensure that all ground connectors are correctly connected and tight (see Figure 1 on page 15 andFigure 2 on page 16.)

12. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. Thereading must not exceed 0.1 ohm.

13. Inspect all cables, connections, and plugs for worn or damaged wiring.

Notices 13

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

15. Replace all covers and access panels.

The printer system diagram and ground locations are shown below. For a detailed description of the signals,see “Chapter 4. Circuit Diagrams” on page 307.

Notices 14

(CRU SENSOR ASSEMBLY)LD SWITCH 5VDC

INTERLOCKDETECTION

LOGIC

FUSERCONTROL

LOGIC

(FUSER COVER SWITCH)

(MCU PWB)

(ROS ASSEMBLY)

LD SCANNERMOTOR

(MAIN MOTOR)

(HVPS)

(FUSER ASSEMBLY)

HEATERASSEMBLY

AC

L

AC

N

(HEATER ROD)

THERMOSTAT THERMALFUSE

SG

SG

(LVPS ASSEMBLY)

FEED BACK

HEATERCONTROL

OUTPUTCONTROL

5VDCSUPPLY

5V

DC

FANCONTROL

24VDCSUPPLY

FUSE

POWERSWITCH

AC L

AC N

(FAN)

hc2m004F

(INTERLOCKSWITCH)

(INTERLOCKSWITCH)

SG

FG

FG

FG

SG

RTN

FAN ON

RT

NF

AN

FA

ST

FA

NA

LA

RM

24

VD

C

TEMPERATURESENSOR

ASSEMBLY

(LD ASSEMBLY) (SCANNER ASSEMBLY)

Figure 1. IBM InfoPrint 20 System Diagram and Ground Locations

Notices 15

Screw,Star Washer

Lug

Typical GND Detail

hc2m131F

Figure 2. Ground Connector Detail

Notices 16

Power-Receptacle Safety-Check

See Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and proceduresbefore performing any of the following tasks. (Electrical Safety for IBM Customer Engineers, S229-8124 maynot be applicable for other countries):

v Checking ac voltage at the power receptaclev Checking ac impedance to ground at the power receptacle

Perform the power receptacle safety check as described in Electrical Safety for IBM Customer Engineers,S229-8124. Use only the applicable high-voltage probes. See the applicable table below for the permitted acvoltage range and record the voltage measured:v See Table 1 on page 18, “Nominal AC Line Voltages at Power Receptacle (110 V ac–120 V ac)”

v See Table 2 on page 18, “Nominal AC Line Voltages at Power Receptacle (220 V ac–240 V ac)”

v See Table 3 on page 19, “Nominal AC Line Voltages at Power Receptacle (220 V ac–240 V ac, 3 PhaseWye Connected)”

Notices 17

Do not continue until the voltages are in the correct range.Table 1. Nominal AC Line Voltages at Power Receptacle (110–120 Vac)

Nominal Line Voltages 100, 110, 120, and127 V ac

Recorded LineVoltages

Phase to Neutral50 Hz 90–119 V ac V ac

60 Hz 90–137 V ac V ac

Phase to Ground50 Hz 90–119 V ac V ac

60 Hz 90–137 V ac V ac

Ground to Neutral <1.0 V ac V ac

Table 2. Nominal AC Line Voltages at Power Receptacle (220 V ac–240V ac)

Nominal Line Voltages 200, 208, 220, 230,and 240 V ac


Phase A to Ground 90–137 V ac V ac

Phase B to Ground 180–254 V ac V ac

Phase A to Phase B50 Hz 180–259 V ac V ac

60 Hz 180–254 V ac V ac

Notices 18

Table 3. Nominal AC Line Voltages at Power Receptacle (220 V ac–240V ac, 3 Phase Wye Connected)

Nominal Line Voltages 3-Phase WyeConnected 200, 208, 220, 230, and 240 V ac


Phase to Neutral50 Hz 180–259 V ac V ac

60 Hz 180–254 V ac V ac

Phase to Ground50 Hz 180–259 V ac V ac

60 Hz 180–254 V ac V ac

Ground to Neutral <1.0 V ac V ac

Notices 19

Electrostatic Discharge (ESD) ProceduresAttention: If discharged into the circuitry of an integrated circuit, static electricity can damage the circuit.

Follow these procedures to prevent damage to ESD-sensitive components;1. Use the ESD Kit.

a. Turn off the printer before you put on the ESD wrist band.b. Connect the wrist band to an unpainted, frame-ground point of the printer.c. Remove the ESD wrist band when working on any part of the printer that has power turned on.d. Do not put the ESD mat near any electrical circuit that has power turned on. The internal resistance

(1 megaohm) in the ESD cable limits the current if it touches a high voltage.e. Do not put the ESD mat near a grounded surface. Ground the ESD mat only through the ESD cable.

The ESD cable supplies a high resistance to ground for your safety. If the ESD mat touches agrounded surface, the high resistance in the ESD cable is bypassed, which causes the ESD mat not towork as expected.

2. Keep an ESD-sensitive part in its original shipping container, usually a protective bag, until you are readyto install it.

3. Make the fewest possible movements to minimize static electricity.4. Touch the metal frame of the printer or the assembly to discharge static electricity in your body before

touching the ESD-sensitive part.5. Hold the ESD-sensitive part by its edges. Do not touch any components, pins, or connectors. If possible,

keep one hand on the frame while you are installing or removing an ESD-sensitive part.6. Do not place an ESD-sensitive part on anything that can provide a discharge path from your body through

the ESD-sensitive part. If you need to put down the ESD-sensitive part, first put it into the ESD protectivewrapper in which it was shipped.

7. Prevent other persons from touching ESD-sensitive parts.

Notices 20

8. Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working withconnectors.

9. Be careful when working with ESD-sensitive parts when the humidity is low. Low humidity increases staticelectricity.

Notices 21

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

AIXAIX/6000IBMInfoPrintOS/2Personal System/2PS/2RISC System/6000WIN-OS/2

The following terms are trademarks or registered trademarks of other companies:

Acrobat Adobe Systems, Inc.Adobe Adobe Systems, Inc.Adobe logo Adobe Systems, Inc.Apple Apple Computer, Inc.Apple logo Apple Computer‘, Inc.Ethernet Xerox CorporationMacintosh Apple Computer, Inc.Microsoft Microsoft Corp.Mylar E. I. du Pont de Nemours & Co., Inc.Novell Novell Inc.PostScript Adobe Systems, Inc.UNIX AT&T CorporationWindows Microsoft Corp.


About This BookThis book is designed to help you service the IBM InfoPrint 20. It describes how to:v Define and solve problems with the printerv Diagnose printer problemsv Service the printerv Locate printer componentsv Remove and replace printer componentsv Identify printer parts for repair and procurementv Diagnose and repair electrical problemsv Perform preventive and periodic maintenance


Related PublicationsTo obtain additional copies of this book or of any related publication, contact your IBM service representative,your authorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755 or 1-919-713-4055.

Document Number

These service documents must be ordered separately:

v IBM InfoPrint 20: Service CD-ROM. The Service CD-ROM includes the service guide for the IBMInfoPrint 20, as well as the customer documents that ship with the printer. These documents areviewable using Adobe Acrobat Reader, which is included on the CD-ROM.

GK2T-9265

v IBM InfoPrint 20: Service Guide (Hardcopy) G544-5514

These books are included with the printer:

v IBM InfoPrint 20: User’s Guide S544-5516

v IBM InfoPrint 20: Quick Setup Poster S544-5515

v IBM InfoPrint 20: Safety and Warranty Information G544-5524

These books are included with the optional network cards:

v IBM Network Printers: Ethernet and Token Ring Configuration Guide G544-5240

v IBM Network Printers: Twinax and Coax Configuration Guide G544-5241

These technical references must be ordered separately:

v IBM Network Printers: PCL5e and PostScript Level 2 Technical Reference S544-5344

v IBM Network Printers: IPDS and SCS Technical Reference S544-5312

About This Book 24

Chapter 1. Getting StartedIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Diagnostic Quick Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Error Codes and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Error Codes 00–19 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Error Codes 20–49 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Error Codes 50–99 and Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Print Quality Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Print Quality Defects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Miscellaneous, Routine Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Completing Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

IntroductionChapter 1. Getting Started quickly guides you through problem isolation.

“Defining the Problem” on page 26 reviews the information necessary to accurately define any printer problem.

With your printer problem defined, “Diagnostic Quick Path” on page 28 directs you to the correct diagnostic orrepair procedure.

See “Miscellaneous, Routine Tasks” on page 35 for miscellaneous or routine tasks.

“Completing Service” on page 36 is a quality-of-service assurance checklist.


Defining the ProblemUse the following as a guide for gathering information about the problem.1. Discuss the problem with the operator. Note information such as error messages, other symptoms (such

as print quality problems), what happened, what type of print job, and other recent problems. Review theprinter history with the customer and obtain or print a printer configuration page (see “Configuration Page”on page 250).

2. Switch on printer power. The printer performs a start-up diagnostic routine that checks the printer controllerand the printer. Almost all failures occurring during this start-up diagnostic routine and during WARM UPcause either an error code or a message.

3. Observe the display on the operator panel.

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

v Is information correctly displayed?v Is the display blank, or does it display solid rectangles within approximately 2-minutes after power is

switched on?v Does WARMING UP display?v Does READY display within approximately 2-minutes?v Is there an error code or message?v View or print the error log looking for recent problems or patterns. See “Error Log” on page 254 for a

description of the error log.

v Try to duplicate the failure noting the following:– The printer fails to print a test print when not connected to a workstation or a network.– The printer fails to print when connected to a workstation, or an Ethernet, token-ring, coax, or twinax

configuration.– The printer prints, but the paper jams.

Chapter 1. Getting Started 26

– The printer prints, but has poor print quality.

Using this information, go to “Diagnostic Quick Path” on page 28.


Solving the Problem

Diagnostic Quick PathUsing the problem information that you have gathered, go to Table 4 on page 29 below. Select the “Symptom ”and “Indication ” that most nearly defines your printer problem, and then “Go To ...” the suggested item toisolate the failure. See “Defining the Problem” on page 26 for a review of the information necessary toaccurately define any printer problem.

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


Table 4. “Diagnostic Quick Path”

Symptom Indication Go To...

Error code with amessage

Error codes 00–19 Table 5 on page 30



Message with No ErrorCode

WARMING UP (Always On)“Operator Panel, Controller, and Power Problems”on page 135

I/O INITIALIZING (Always On)“Ethernet / Token-Ring NIC Printing Problems” onpage 150

IBM INFOPRINT 20 (Always On)“Operator Panel, Controller, and Power Problems”on page 135

Other

Print quality problem Table 8 on page 34

Operator panel (blank, light or dark rectangles,pushbuttons), controller, or power problems

“Operator Panel, Controller, and Power Problems”on page 135

Problems printing from a Ethernet/Token-Ringconfiguration

“Ethernet / Token-Ring NIC Printing Problems” onpage 150

Problems printing from a Twinax/Coaxconfiguration

“Twinax / Coax NIC Printing Problems” onpage 179

EP (toner) cartridge is out of toner, and an errorcode 02 TONER LOW not displayed

“Toner Low and No Error Code 02 Displayed” onpage 142

Intermittent or Random Problems “Intermittent or Random Problems” on page 133

Miscellaneous, routine tasks Table 9 on page 35

Environmental problem (temperature, humidity,ventilation, space, supplies storage)

IBM InfoPrint 20: User’s Guide


Error Codes and MessagesNote: See “Status Messages” on page 239 for status messages displayed during normal operation.

Error Codes 00–19 and Messages

From Table 5, select the “ Error Code Message ”, and then “ Go To ...” the suggested procedure to isolatethe problem.Table 5. Error Codes 00–19 and Messages

Error Codes 00–19 and Messages Error Codes 00–19 and Messages

Error Code Message Go To... Error Code Message Go To...

02 TONER LOW “02 TONER LOW” on page 4612 MANUALLY LOADpaper_size IN AUX

“12 MANUALLY LOAD paper_size INAUX” on page 64

03 2000 SHEET INPUTCOVER OPEN

“03 2000 SHEET INPUT COVEROPEN” on page 49

14 ADJUST PAPERGUIDES IN TRAY n

“14 ADJUST PAPER GUIDES INTRAY n” on page 64

04 TONER CART MISSING“04 TONER CART MISSING” onpage 50

15 2000 SHEET INPUTNOT READY

“15 2000 SHEET INPUT NOTREADY” on page 64

06 TOP COVER OPEN “06 TOP COVER OPEN” on page 52 16 TRAY n MISSING “16 TRAY n MISSING” on page 65

09 DUPLEX COVER OPEN“09 DUPLEX COVER OPEN” onpage 54

17 TRAY OPTION ERROR“17 TRAY OPTION ERROR” onpage 68

10 FUSER COVER OPEN“10 FUSER COVER OPEN” onpage 55

17 2000 SHEET INPUTERROR

“17 2000 SHEET INPUT ERROR” onpage 68

11 LOAD <size> IN<source>

“11 LOAD <size> IN <source>” onpage 58






20 PAPER JAM “20 PAPER JAM” on page 69 31 MEMORY ALLOC ERROR“31 MEMORY ALLOC ERROR” onpage 101

21 PAPER JAM “21 PAPER JAM” on page 73 32 PRINT OVERRUN “32 PRINT OVERRUN” on page 101

22 PAPER JAM “22 PAPER JAM” on page 8340 MEMORY OPTIONERROR

“40 MEMORY OPTION ERROR” onpage 101

23 PAPER JAM “23 PAPER JAM” on page 8441 NETWORK OPTIONERROR

“41 NETWORK OPTION ERROR” onpage 102

24 PAPER JAM “24 PAPER JAM” on page 8942 NETWORK OPTIONERROR


26 PAPER JAM “26 PAPER JAM” on page 94 43 PS OPTION ERROR“43 PS OPTION ERROR” onpage 103

27 PAPER ERROR<source>

“27 PAPER ERROR <source>” onpage 94

44 IPDS OPTION ERROR“44 IPDS OPTION ERROR” onpage 103

29 OUTPUT FULL “29 OUTPUT FULL” on page 98 45 OPTION ERROR “45 OPTION ERROR” on page 104

30 MEMORY OVERFLOW“30 MEMORY OVERFLOW” onpage 101

46 NETWORK OPTIONERROR







50 ERROR CALL FORSERVICE

“50 ERROR CALL FOR SERVICE”on page 105

71 DISK ERROR “71 DISK ERROR” on page 124









80 ADD MEMORY FORIPDS

“80 ADD MEMORY FOR IPDS” onpage 125



80 ADD MEMORY FORPAGES, ESC/P

“80 ADD MEMORY FOR PAGES,ESC/P” on page 125



81 INSUFFICIENTMEMORY FOR IPDS

“81 INSUFFICIENT MEMORY FORIPDS” on page 125



81 INSUFFICIENTMEMORY FOR PAGES

“81 INSUFFICIENT MEMORY FORPAGES” on page 125



82 CX SEND STATE “82 HOST TIMEOUT” on page 126



83 CX SEND STATE “83 CX SEND STATE” on page 126



84 NO FONT SIMM FORPAGES, ESC/P

“84 NO FONT SIMM FOR PAGES,ESC/P” on page 126


Print Quality ProblemsThe quality of the printed image depends upon many factors, some controlled by the customer and some byservice. The following customer controlled items should be as described in the IBM InfoPrint 20: User’s Guide:v Tonerv Paper, envelopes, or transparenciesv Consumable supplies replenished at the correct intervalsv Stable operating environment

– Temperature– Humidity

v Location– On a level surface– Proper ventilation– Shielded from direct rays from the sun– Low dust content– Not near water outlets, steamers, electric heaters, volatile gases, or open flame

v Supplies– Storage at the warehouse– Storage in the printer operating environment

Service should perform the following:v Replace worn partsv Check printer performance and print quality at every visit.


Print Quality Defects

Before analyzing print quality (PQ) problems, verify that no supply item, such as the EP cartridge, needsreplacing. Also, check the items listed under “Print Quality Problems” on page 33.

From Table 8, select the “ Problem ”, and then “ Go To ...” the suggested procedure to isolate the failure.Table 8. Print Quality Diagnostics Quick Path

Problem Go To...

Background “Background” on page 184

Black Horizontal Stripes “Black Horizontal Stripes” on page 195

Black Prints “Black Prints” on page 188

Blank Prints “Blank Prints” on page 191

Damaged Print “Damaged Print” on page 196

Fusing “Fusing, Not Fused or Partially Fused Image” on page 200

Light (Undertoned) Prints “Light (Undertoned) Prints” on page 203

Residual Image “Residual Image” on page 208

Skewed Image “Skewed Image” on page 212

Spots “Spots” on page 216

Streaks, Horizontal “Streaks, Horizontal” on page 219

Streaks, Vertical “Streaks, Vertical” on page 223

Unusual Patterns “Unusual Patterns” on page 227

Voids “Voids” on page 229

Voids, Horizontal Band “Voids, Horizontal” on page 232

Voids, Vertical Band “Voids, Vertical” on page 236


Miscellaneous, Routine TasksThis section guides you to performing routine printer tasks. When the tasks are completed, go to “CompletingService” on page 36.

From Table 9, select the “ Task ”, and then “ Go To ...” the suggested procedure.Table 9. “Routine Tasks”

Task Go To...

Cleaners “Cleaners and Lubricants” on page 588

Configuration page, running “Configuration Page” on page 250

Error log, using “Error Log” on page 254

Installing the printer IBM InfoPrint 20: User’s Guide

Locating assemblies and parts “Chapter 5. Locations” on page 360

Lubricants “Cleaners and Lubricants” on page 588

Power-Receptacle Safety-Check “Power-Receptacle Safety-Check” on page 17

Relocating the printer IBM InfoPrint 20: User’s Guide

Replenishing supplies IBM InfoPrint 20: User’s Guide

Run test prints “Test Prints” on page 251

Safety Inspection “Safety Inspection” on page 12

200K usage kit“Chapter 7. Preventive Maintenance and Usage Kit” onpage 543


Completing ServiceNote: If you replaced a part that did not correct the problem, reinstall the original part.

If the printer has not been fixed using the procedures that you were directed to perform, return to “DiagnosticQuick Path” on page 28. Ensure that you have correctly interpreted the available information, and then definethe problem again. If a solution is not found, call your next level of support (see “Appendix D. TechnicalSupport” on page 602).

Use the following as a guide to ensure high quality printer operation:

1. Ensure the following:a. All internal cables and connectors are correctly connected.b. All covers, doors, panels, and trays are in place.c. Any workstation or network cable is connected.d. All power cords are connected.

2. Switch on printer power and ensure the following:a. IBM INFOPRINT 20 displays.b. WARMING UP displays.c. READY displays within approximately 2-minutes or the printer begins printing if a job is in the print

queue.3. Run test prints from the operator panel to ensure high quality output. Show these to the operator.4. Have the operator run a print job.5. Clean the work area.6. Clean the printer covers with a dry cleaning cloth; if necessary, use water and a mild detergent

(non-ammonia).7. Return control of the printer to the operator.


Chapter 2. Diagnosing ProblemsGeneral Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Using Diagnostic Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Error Codes with Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4502 TONER LOW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4603 2000 SHEET INPUT COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4904 TONER CART MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5006 TOP COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5209 DUPLEX COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5410 FUSER COVER OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5511 LOAD <size> IN <source> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5812 MANUALLY LOAD paper_size IN AUX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6414 ADJUST PAPER GUIDES IN TRAY n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6415 2000 SHEET INPUT NOT READY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6416 TRAY n MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6517 TRAY OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6817 2000 SHEET INPUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6820 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6921 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7322 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8323 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8424 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8926 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9427 PAPER ERROR <source> . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9429 OUTPUT FULL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9830 MEMORY OVERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10131 MEMORY ALLOC ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101


32 PRINT OVERRUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10140 MEMORY OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10141 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10242 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10243 PS OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10344 IPDS OPTION ERROR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10345 OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10446 NETWORK OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10450 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10551 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10852 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10953 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11454 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11955 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12056 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12261 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12362 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12363 ERROR CALL FOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12471 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12472 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12473 DISK ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12580 ADD MEMORY FOR IPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12580 ADD MEMORY FOR PAGES, ESC/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12581 INSUFFICIENT MEMORY FOR IPDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12581 INSUFFICIENT MEMORY FOR PAGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12582 HOST TIMEOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12683 CX SEND STATE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12684 NO FONT SIMM FOR PAGES, ESC/P. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

Printer Problems without Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127Fuse or Power Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Chapter 2. Diagnosing Problems 38

Intermittent or Random Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133Operator Panel, Controller, and Power Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135Toner Low and No Error Code 02 Displayed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

Other Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14424V Power Supply to MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144Electrical Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146Ethernet / Token-Ring NIC Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163Paper Size Switch - 500-Sheet Paper Trays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165Pick Up Solenoid (Auxiliary Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172Toner Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176Twinax / Coax NIC Printing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

Print Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184Black Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188Blank Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191Black Horizontal Stripes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195Damaged Print. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196Fusing, Not Fused or Partially Fused Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200Light (Undertoned) Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203Residual Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208Skewed Image. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212Spots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216Streaks, Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219Streaks, Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223Unusual Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229


Voids, Horizontal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232Voids, Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236

Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239


General InformationThe Diagnostic Quick Path should have directed you to this section to analyze your printer problem.

1. Diagnostics assume there are no code problems in the printer controller. If you are unable to fix aproblem using the diagnostics, we recommend that you replace the printer controller and obtain the latestlevel code.

2. Diagnostics frequently use new or ″known good″ components as diagnostic tools. We recommend youcarry a spare Toner Cartridge (EP Cartridge), MCU PWB, Printer Controller PWB, and Power SupplyPWB.

3. Unless indicated otherwise, the instruction ″switch ON main power″ means for you to SWITCH ON printerpower and let the printer proceed through power-on diagnostics and warm-up until it is on-line and readyto print.

4. Unless indicated otherwise, you should inspect and confirm the status of those components listed underthe title of ″SUSPECT COMPONENTS″ at the first part of each diagnostic. The inspection items are:v Installed properly?v Not damaged or deformed?v Not contaminated with foreign material?

5. If you cannot isolate the problem using the diagnostics, replace each component listed under the title of″SUSPECT COMPONENTS″ at the first part of each diagnostic, one at a time, until the problem is fixed.

6. Conventions used to represent connectors,v P/J XX means that the Plug and its corresponding Jack are connected.v PXX means that the Plug is disconnected. (Unless this plug is soldered to a PWB).v JXX means that the Jack is disconnected. (Unless this jack is soldered to PWB).

7. When you are instructed to take a voltage reading between ″P/J A-B and P/J X-Y″, place the red probe(+) of your meter on pin B of P/J A, and place the black probe (-) of your meter on pin Y of P/J X.

8. When you are instructed to take a voltage reading between ″P/J X and P/J Y″ (without specified pinnumbers), check all voltage carrying pins. See the Wiring Diagrams for signals and pin numbers.


9. Plug numbers are indicated on the circuit board. In there are 8 pins in a plug, you can find a 1 (or A) atone end and an 8 or (H) at the other end. The other pins, such as 6, are found by counting from oneend.

10. When you are instructed to take a voltage reading, the black probe (-) is generally connected to a pinthat is either RTN (Return) or FG (Frame Ground) in place of any SG pin or test point.

11. Unless an diagnostic instructs you otherwise, before measuring voltages make sure the printer isswitched ON, the Print Cartridge and the Paper Cassette are installed, and the Exit Cover is closed(Interlock Switch is actuated).

12. All voltage values given in the diagnostics are approximate. Measured voltages may vary more than 25%from the values stated in the diagnostics. The main purpose of most voltage readings taken in thediagnostics is to determine whether or not a component is receiving the correct high voltage value fromthe power supply and if gating (a voltage drop) occurs during component actuation. Gating signals maybe nothing more than a pulse, resulting in a momentary drop in voltage that may be difficult or impossibleto read on a multimeter.

13. Diagnostics may instruct you to remove or replace a component. See “Chapter 6. Removal Procedures,Adjustments” on page 394 for information on how to remove and reinstall a component.

14. When a diagnostic instructs you to replace a component and that component is part of a larger assembly,you should replace the entire assembly.


Using Diagnostic Tables1. Each numbered step in a diagnostic instructs you to perform a certain action or procedure.2. The action box may contain additional information and numbered substeps to perform the action.3. The action is followed by a question.4. If your response to the question is Yes, follow the instructions for a Yes reply.5. If your response to the question is No, follow the instructions for a No reply.6. Diagnostics often ask you to take voltage readings at certain test points. “Chapter 4. Circuit Diagrams” on

page 307 and “Chapter 5. Locations” on page 360 contain information on test point locations and signalnames.

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


Diagnostics“Diagnostic Quick Path” on page 28 is the entry point for all problems. If at any point the diagnostic to whichyou have been directed does not solve the problem, return to the Diagnostic Quick Path.

Diagnostics are listed as follows:

1. “Error Codes with Messages” on page 45Error codes with messages are described here.

2. “Printer Problems without Error Codes” on page 127You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post anerror code.

3. “Other Diagnostics” on page 144These are secondary diagnostics pointed to by other diagnostics.

4. “Print Quality” on page 184Each of these diagnostics has an illustration of the print quality symptom discussed in the diagnostic.


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


02 TONER LOW

Meaning : The EP Cartridge is nearing end-of-life and should be replaced. This error can also occur if the EPCartridge is misaligned, caused by the side guides or BTR assembly.

Action : Press the Continue key to continue printing (the TONER LOW message remains on the display).Ensure that a new EP cartridge is available. When the print quality becomes unacceptable, install a new EPcartridge.

The TONER LOW item on the Paper Menu lets you specify whether or not you want the printer to stopprinting when it detects a TONER LOW condition.

If toner is low and error code 02 does not display, go to “Toner Low and No Error Code 02 Displayed” onpage 142.

If this action does not fix the problem, go to Table 10.Table 10. 02 TONER LOW

Step Actions and Questions Yes No

SUSPECT COMPONENTS

v EP Cartridge (Asm-Index: 11-40, page 572)

v Toner Sensor Assembly (Asm-Index: 5-13, page 557)

v Toner Relay Harness (Asm-Index: 12-18, page 575)

v MSI Bracket Assembly (Asm-Index: 5-7, page 557)

v MCU PWB (Asm-Index: 12-8, page 575)

1.EP CARTRIDGE

Install a new EP Cartridge.

Does the Error Code 02 TONER LOW still appear?

Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.


Table 10. 02 TONER LOW (continued)


2.

FUNCTION OF TONER SENSORa. Use “D21 SENSOR TEST” on page 261 to check the function of the Toner

Sensor Assembly.Note: The Pop Up Unit must be closed in the next step.

b. Depress the switch with a non-magnetized piece of steel.

Does the Toner Sensor function correctly?

Replace theMCU, or there isan EP cartridgealignmentproblem.

Go to step 3

3. TONER SENSOR CONNECTION

Is the Toner Sensor connection (P/J221) OK?

Go to step 4 Repair as needed

4.TONER SENSOR ASSEMBLY (Asm-Index: 5-13, page 557)

Install a new Toner Sensor Assembly (See page 462).

Is the problem fixed?

Verify the fix. Alsoverify that theproblem jobprints.

Go to step 5

5.

TONER RELAY HARNESS

Inspect the Toner Relay Harness (P/J22 at the MCU; P/J222 at the TonerSensor Harness).

Is the harness OK?


6.MSI BRACKET ASSEMBLY (Asm-Index: 5-7, page 557)

Replace the MSI Bracket Assembly (See page 457).



Go to the laststep of thisdiagnostic.


Table 10. 02 TONER LOW (continued)


7.

End of diagnostic and a problem remainsv Exchange the remaining suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:

– All connectors and wiring associated with the suspected FRUs– All ground connectors (see “Printer Safety Inspection” on page 13)

– Environmental conditions (temperature, humidity, ventilation)

If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do not find asolution, call your next level of support (see “Appendix D. Technical Support” on page 602).


03 2000 SHEET INPUT COVER OPEN

Meaning : The cover at the back of the 2000-Sheet Input Drawer is open.

Action : Close the cover. If the message persists, make sure both corners of the cover are completely closed.Also check for paper inside the cover.

Error Code Diagnostic Procedure : “03 2000-SHEET COVER OPEN” on page 708.


04 TONER CART MISSING

Meaning : The EP Cartridge is not in place or is installed incorrectly.

Action : Open the printer and make sure the EP cartridge is seated correctly. If you have not installed a EPcartridge, do so now.

If this action does not fix the problem, go to Table 11.Table 11. 04 TONER CART MISSING


SUSPECT COMPONENTS


v CRU Sensor Assembly (Asm-Index: 11-15, page 572), includes cable


1.Install a new EP Cartridge.

Does the LCD display a 04 TONER CART MISSING?


2.CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)

Press and release the CRU Sensor Assembly.

Does the CRU Sensor Assembly lever move smoothly?

Go to step 3 Replace the CRUSensor Assembly(See page 503)

3.

FUNCTION OF CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)

a. Use “D21 SENSOR TEST” on page 261 to check the function of the CRUSensor Assembly.

b. Actuate the CRU Sensor Assembly.

Does the CRU Sensor function correctly?

Possibleintermittent orrandom problems(See page 133)

Go to step 4


Table 11. 04 TONER CART MISSING (continued)


4.CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)

Replace the CRU Sensor Assembly (See page 503).



Go to step 5

5.FRAME ALIGNMENT

When you close the top cover, is the CRU Sensor activated?

Replace the MCUPWB (See page526 or 529)

Repair as needed

6.






06 TOP COVER OPEN

Meaning : The top cover is open.

Action : Close the cover.

If this action does not fix the problem, go to Table 12.Table 12. 06 TOP COVER OPEN


SUSPECT COMPONENTS

v Interlock Switch (Asm-Index: 12-1, page 575)

v Interlock Actuator (Asm-Index: 11-19, page 572)

v ROS Support (Asm-Index: 11-18, page 572)


v LVPS Assembly (Asm-Index: 12-4, page 575)

1.

INTERLOCK SWITCH (Asm-Index: 12-1, page 575) and INTERLOCKACTUATOR (Asm-Index: 11-19, page 572)

a. Open and close the Pop Up Unit.b. Inspect the movement of the Interlock Switch.

Does the actuator tab press down on the Interlock Switch lever?

Go to step 2 Replace theInterlock Actuatoror the InterlockSwitch (See page513)

2.

FUNCTION OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575)

a. Use “D21 SENSOR TEST” on page 261 to check the Interlock Switch.

b. Open and close the Pop Up Unit.

Does the Interlock Switch function correctly?


Go to step 3


Table 12. 06 TOP COVER OPEN (continued)


3.

CONTINUITY OF INTERLOCK SWITCH (Asm-Index: 12-1, page 575)

a. Remove the Controller Assembly (See page 535).

b. Disconnect P/J21 and P/J123.c. Press and release the Interlock Switch.d. Check for the continuity between J21-1 <=> J123-1.

Is there continuity between J21-1 <=> J123-1 when you press theInterlock Switch and no continuity when you release it?

Go to step 4 Replace theInterlock Switch(See page 513)

4.

LVPS ASSEMBLY (Asm-Index: 12-4, page 575)

a. Reconnect P/J21 from the MCU PWB and P/J123 from the LVPSAssembly.

b. Open and Close the Pop Up Unit.c. Measure the voltage between P/J21-1 <=> P/J11-1.

Is the voltage between P/J21-1 <=> P/J11-1 24VDC when you close thePop Up Cover Assembly, and 0VDC when you open it?


Verify that thecover activatesthe sensorcorrectly, thenreplace the LVPSAssembly (Seepage 521)

5.






09 DUPLEX COVER OPEN

Meaning : A cover on the duplex unit is open.

Action : Make sure both duplex covers are closed.

Error Code Diagnostic Procedure : “09 DUPLEX COVER OPEN” on page 607.


10 FUSER COVER OPEN

Meaning : The Fuser Cover (the Main Interlock Switch) is open.

Action : Close the cover.

If this action does not fix the problem, go to Table 13.Table 13. 10 FUSER COVER OPEN


SUSPECT COMPONENTS

v Duplex Interface PWB (Asm-Index: 12-6, page 575) or it’s MCU connectionNote: The Duplex Interface PWB can appear to be seated when it is not.

v Fuser Cover Switch (Asm-Index: 12-2, page 575)

v Fuser Cover Assembly (Asm-Index: 1-1, page 548)


v Fuser Switch Cover Harness (Asm-Index: 12-13, page 575)

1.

FUSER COVER SWITCH (Asm-Index: 2-2, page 550)

a. Open and close the Fuser Cover Assembly (Asm-Index: 1-1, page 548).

b. Inspect the contact of the Fuser Cover with the Fuser Cover Switch(Asm-Index: 12-2, page 575).

c. Ensure the switch is installed properly and the bracket is not bent.d. Push and release the Fuser Cover Switch manually.

Does the Fuser Cover Assembly actuate the Fuser Cover Switch, anddoes the Fuser Cover Switch move smoothly?

Go to step 2 Replace theFuser CoverAssembly (Seepage 400) or theFuser CoverSwitch (See page516)


Table 13. 10 FUSER COVER OPEN (continued)


2.

CONTINUITY OF FUSER COVER SWITCH (Asm-Index: 12-2, page 575)

a. Open the Fuser Cover (Asm-Index: 1-2, page 548).

b. Remove the Fuser Cover Switch (See page 516).

c. Unplug P/J190 from the Fuser Cover Switch (See page 516).

d. Press and release the actuator of the Fuser Cover Switch.e. Check continuity from 1A to 1B, and 2A to 2B on the Fuser Cover Switch

(the pins are labeled in the plastic on the bottom of the switch).

Is there continuity on the pair of switch pins when you press theactuator and no continuity when you release it?

Go to step 3 Replace theFuser CoverSwitch (See page516)

3.

DUPLEX INTERFACE PWB (Asm-Index: 12-6, page 575)


b. Find the Duplex Interface PWB. It is the small board that bridges theduplex option connector (above the power connector) to the MCU PWB(P/J18).

c. Ensure that the connector between the MCU PWB (P/J18) and the DuplexInterface PWB is properly seated.

Note: The Duplex Interface PWB can appear to be seated when it is not.

Is the Duplex Interface PWB properly seated?

Go to step 4 Reconnect P/J18.Verify the fix. Alsoverify that theproblem jobprints.

4.The Fuser Cover harness connects to the Duplex Interface PWB at P/J180.This connector is located on the top on the Duplex Interface PWB. P/J180 canbe easily damaged.

Is P/J180 OK?

Go to step 5 Replace theDuplex InterfacePWB (See page524).


Table 13. 10 FUSER COVER OPEN (continued)


5.

One of the following parts is bad:v Duplex Interface PWB (Asm-Index: 12-6, page 575)

v Fuser Cover Harness (Asm-Index: 12-13, page 575)


6.






11 LOAD <size> IN <source>

Meaning : The tray is out of paper, the tray contains the wrong size paper, or the tray is loaded incorrectly. Themessage identifies the size of paper (size) and the tray (source) that needs paper. If the message indicates atray you do not think you specified, automatic tray switching may be enabled. This error can occur if paperempty or size sensing is bad in any paper source.

Actions :v If the tray is empty, fill it. The printer will resume printing.v If the tray contains the wrong size paper, you have two choices: to use the current paper size, press the

Continue key; otherwise, load the correct paper size into the tray.v If the tray contains the right size paper, make sure the paper is loaded correctly. Check the paper guides.

The AUTOSENSED PAPER section of the printer configuration page shows what size paper the printerpaper size sensors have determined is in each tray.

v If the tray is empty, refill it. The printer will resume printing.v If you are printing a printer configuration page, make sure Letter or A4 size paper is loaded in the default

tray.


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


SUSPECT COMPONENTS

v Problems only from Auxiliary Tray:– PAPER MENU/AUXSIZE setting wrong– MSI No Paper Sensor (Asm-Index: 5-9, page 557), includes harness

– MSI No Paper Actuator (Asm-Index: 5-10, page 557)

v Tray empty problems only from Tray 1:– Cassette No Paper Sensor (Asm-Index: 3-11, page 553)

– Cassette No Paper Actuator (Asm-Index: 3-16, page 553)

– Feeder Harness (Asm-Index: 3-12, page 553)

v Tray size problems with Tray 1 and possibly Tray 2 or 3v Feeder PWB (Asm-Index: 3-1, page 553)

v Tray Harness (Asm-Index: 12-17, page 575)

v Problems only with one Optional Tray:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page

697)

– 2000-Sheet Input Option: Analyze using “Appendix H. 2000-Sheet InputDrawer Option” on page 703

v General:– MCU PWB (Asm-Index: 12-8, page 575)


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


1.

TRAY EMPTY SENSINGa. During the next steps, record which sources print OK and which sources

are involved with the problem. Clear jams (open and close the top cover)as necessary. Note that CONFIG PAGES will try a reprint after the jam iscleared — you can press ONLINE to cancel.

b. Set PAPER MENU/TRAYSWITCH=OFF.Note: Tray switching may affect behavior with real jobs. CONFIG pages willtry to print only on Letter or A4 paper that is loaded.c. Load Tray 1 (the standard 500 sheet input) with letter or A4 paper (empty

all other paper sources). Set the PAPER MENU/SOURCE=TRAY 1. Try toprint using TEST MENU/CONFIG PAGE. If a jam occurs, clear it.

d. Load the Auxiliary Tray (the flip-down MSI input at the front of the printer).Ensure that PAPER MENU/ AUXSIZE matches the loaded papersize/orientation. Set PAPER MENU/SOURCE=AUX. Try to print anotherCONFIG PAGE.

e. If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeatthe above steps for Tray 2.

f. If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 3.

Did the 11 LOAD <size> IN <source> ever occur?

Look at aCONFIG pagefrom anothersource. Verify thatthe loaded papermatchesAUTOSENSEDPAPER details. Ifnot, go to “PaperSize Switch -500-Sheet PaperTrays” onpage 165. IfAUTOSENSEDPAPER is OK, goto step 2.

For othermessages orsymptoms, go to“Chapter 1.Getting Started”on page 25. If

there is nomessage, theuser may besending jobs witha size/sourcemismatch.

2.

Does the problem appear when using Tray 2 or 3? Go to “11 LOAD<size> IN TRAYn” on page 663.Or analyze using“Appendix H.2000-Sheet InputDrawer Option” onpage 703.

Go to step 3




3. Does the 11 LOAD <size> IN <source> error code appear when you feedpaper from Auxiliary Tray (MSI)?

Go to step 4 Go to step 8

4.

MSI NO PAPER ACTUATOR (Asm-Index: 5-10, page 557)

Insert then remove a piece of paper into the Multi Sheet Inserter.

Do the MSI No Paper Actuator move smoothly when paper is insertedthen removed?

Go to step 5 Repair or replacethe MSI No PaperActuator (Seepage 460)

5.

MSI NO PAPER SENSORa. Use “D21 SENSOR TEST” on page 261 to check the MSI No Paper

Sensor (Asm-Index: 5-9, page 557).

b. Press and then release the MSI No Paper Actuator.

Does the MSI No Paper Sensor work correctly?

Go to step 8.Possibleintermittent orrandom problems(See page 133)

Go to step 6

6.

Replace the following:v MSI Bracket Assembly (See page 457)

v MSI No Paper Sensor (See page 460)



Go to step 7

7.

The MSI no paper sensing problem could be caused by one of the following:v MCU PWB (Asm-Index: 12-8, page 575)

v High Harness Assembly (Asm-Index: 6-5, page 559)


v LVPS Harness (Asm-Index: 12-14, page 575)




8.

PAPER CASSETTE (Asm: 2, page 550)

There is problem with Tray 1 no paper sensing.

a. Remove the Paper Cassette from the printer.b. Remove the Cassette Cover (Asm-Index: 2-25, page 550) and all paper

from the Paper Cassette.

c. Insert the Paper Cassette into the printer and inspect the Bottom PlateAssembly (Asm-Index: 2-10, page 550).

Is the Bottom Plate Assembly raised?

Go to step 9 Replace thePaper Cassette

9.CASSETTE NO PAPER ACTUATOR (Asm-Index: 3-16, page 553)

Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553).

Does the Cassette No Paper Actuator move smoothly?

Go to step 10 Replace theCassette NoPaper Actuator(See page 436)

10.

CASSETTE NO-PAPER SENSOR (Asm-Index: 3-11, page 553)

a. Use “D21 SENSOR TEST” on page 261 to check the Cassette No PaperSensor.

b. Release the tray 1 Low Paper Actuator (Asm-Index: 3-10, page 553)

c. Actuate the Cassette No Paper Actuator (Asm-Index: 3-16, page 553).

Does the Cassette No Paper Sensor function correctly?


Go to step 11

11.CASSETTE NO PAPER SENSOR (Asm-Index: 3-11, page 553)

Replace the Cassette No Paper Sensor (See page 430).



Go to step 12




12.






12 MANUALLY LOAD paper_size IN AUX

Meaning : The auxiliary tray requires paper. The message indicates the required size (paper_size).

Action : Place another sheet of paper or other media in the auxiliary tray and press the Continue key. If youreceive this message and you do not want the manual printing function, set MANUAL to OFF on the PaperMenu or using your printer driver.

14 ADJUST PAPER GUIDES IN TRAY n

Meaning : Paper guides in the specified tray need adjusting.

Action : Adjust the paper guides.

15 2000 SHEET INPUT NOT READY

Meaning : The elevator mechanism in the 2000-Sheet Input Drawer is moving or out of position.

Action : Wait for the elevator to stop moving. Make sure the 2000-Sheet Input Drawer is in place.

Error Code Diagnostic Procedure : “15 TRAY n NOT READY” on page 709.


16 TRAY n MISSING

Meaning : Paper Cassette (Tray 1), Tray 2 or Tray 3 are not in place.

Action : Open and close the tray. If you have not installed the tray, do so at this time.

If this action does not fix the problem, go to Table 15.Table 15. 16 TRAY n MISSING


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)



1.

Does the Error Code specify Tray 2 or Tray 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661

Go to step 2


Table 15. 16 TRAY n MISSING (continued)


2.Remove and reinstall the affected paper cassette (Asm: 2, page 550).

Does the 16 TRAY n MISSING error code still appear?


3.

PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS

Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page553).Note: If the switches are activated, answer No to the following question.

Do the Size Cam states match the loaded paper size? (see “Paper SizeSwitch - 500-Sheet Paper Trays” on page 165)


4.

PAPER SIZE CAM (Asm-Index: 2-20, page 550) MECHANICS

Inspect the suspect components and their settings relating to the Size Camas:

v End Guide Plate (Asm-Index: 2-14, page 550)

v Paper End Guide (Asm-Index: 2-15, page 550)

v End Guide Spring (Asm-Index: 2-16, page 550)

v End Guide (Asm-Index: 2-17, page 550)

v Pivot Plate (Asm-Index: 2-18, page 550)

v Sector Gear (Asm-Index: 2-19, page 550)

v Size Cam

Is there any damage or wrong setting on those suspect components?

Replace damagedparts, adjustsetting, or install anew cassette

Go to step 6


Table 15. 16 TRAY n MISSING (continued)


5.

PAPER SIZE SWITCHa. Remove the Paper Cassette (Asm: 2, page 550).

b. Use “D21 SENSOR TEST” on page 261 to check the function of the PaperSize Switch.

c. Reach inside the paper feeder and press and release each Size Actuator(Asm-Index: 3-8, page 553), one Actuator at a time, pressing ENTERbetween each Actuator tested.

Do the Size Switches function correctly?


Go to “Paper SizeSwitch -500-Sheet PaperTrays” onpage 165

6.






17 TRAY OPTION ERROR

Meaning : An optional paper tray was detected previously, but is no longer detected.

Action : Make sure that the tray is installed correctly.

Error Code Diagnostic Procedure : “17 TRAY n OPTION ERROR” on page 664.

17 2000 SHEET INPUT ERROR

Meaning : The 2000-Sheet Input Drawer is not ready.

Action : Make sure that the 2000-Sheet Input Drawer has power and is properly installed.

Error Code Diagnostic Procedure : “17 2000 SHEET INPUT ERROR” on page 710.


20 PAPER JAM

Meaning : There is a paper jam at the Exit Sensor (Exit Photo Sensor).

Action : Remove jammed paper from the paper path. Open and close the top cover.

If this action does not fix the problem, go to Table 16.Table 16. 20 PAPER JAM


SUSPECT COMPONENTS

v Fuser Assembly (Asm-Index: 8-1, page 564), includes Exit Sensor

v Duplex Unit (Asm: 30, page 652)



v Exit Cover (Asm-Index: 1-12, page 548)

1. PAPER CONDITIONS

Is the paper wrinkled, damaged, or damp?

Replace withfresh, dry paper

Go to step 2

2. Switch ON main power.

Is 20 PAPER JAM displayed when you Switch ON power?


3.

PAPER AT EXIT ACTUATOR (Asm-Index: 8-24, page 564)

a. Open the Fuser Cover.b. Open the Fuser Access Cover.

Is there paper at the Exit Actuator inside the Fuser?

Remove thepaper. Go to step4.

Go to step 10


Table 16. 20 PAPER JAM (continued)


4.Is the Error Code 20 PAPER JAM gone? Verify the fix. Also

verify that theproblem jobprints.

Go to step 5

5.

DUPLEX UNIT (Asm-Index: 30-1, page 652)

Does the problem appear using the Duplex Unit?

Ensure that theDuplex Unit isinstalled correctlyand plugged intothe duplexconnection. If it is,go to“Appendix E.Duplex UnitOption” onpage 604.

Go to step 6

6.

CAUTION:<2-35> Remove all watches, rings, jewelry, and other articles(such as a necktie) that may catch on printer parts beforeworking in this area.

ROTATION OF EXIT ROLL ASSEMBLY (Asm-Index: 9-31,page 567)

a. Switch ON main power.b. Inspect the rotation of the Exit Roll Assembly and the Pinch

Roll of the Fuser Top Cover Assembly (Asm-Index: 8-6, page564) during the warm up period.

Does the Exit Roll Assembly and the Pinch Roll of the FuserTop Cover Assembly rotate smoothly?

Go to step 7 Replace theFuser Assembly(See page 487)




7.

EXIT ROLL ASSEMBLY (Asm-Index: 9-31, page 567)

a. Run a Test Print.b. Inspect the paper path through Exit Roll Assembly and the Pinch Roll of

the Fuser Top Cover Assembly (Asm-Index: 8-6, page 564).

Does the paper pass through the Exit Roll Assembly and the Pinch Rollof the Fuser Top Cover Assembly?


8.PAPER CASSETTE

Does Error Code 20 PAPER JAM appear only when using the PaperCassette?

Go to “27 PAPERERROR<source>” onpage 94

Go to step 9

9.

EXIT ACTUATOR (Asm-Index: 8-24, page 564)

a. Remove the Exit Cover (See page 414).

b. Open the Fuser Cover (Asm-Index: 1-2, page 548) and the Fuser RearCover (Asm-Index: 8-11, page 564).

c. Actuate and release the Exit Actuator.d. Inspect the position of the lever.

Is the arm of the Exit Actuator away from the detecting points of the ExitSensor when you actuate the Actuator, and does the arm shield thedetecting points when you release it?


10.

EXIT SENSOR (Asm-Index: 8-25, page 564)

Use “D21 SENSOR TEST” on page 261 to check the Exit Sensor function (youwill need to override the fuser cover switch).

Does the Exit Sensor function correctly?

Bad MCU PWB(See page 526 or529), or possibleintermittent orrandom problems(See page 133)

Go to step 11




11.

FUSER ASSEMBLY (Asm-Index: 8-1, page 564)

Replace the Fuser Assembly (See page 487).Note: The Fuser is part of the Usage Kit.



Go to step 12

12.

The Fuser exit sensing is bad, one of the following parts is bad:v High Harness Assembly (Asm-Index: 6-5, page 559)




13.






21 PAPER JAM

Meaning : Misfeed jam. There is a paper jam between the paper inputs (Tray 1, 2, 3, AUX Tray) and theRegistration Sensor.

Action : Remove jammed paper from the paper path. Make sure paper is loaded correctly. Open and close thetop cover.

Note: If the 21 PAPER JAM error occurs only when paper re-enters the printer from the duplex option, go to“22 PAPER JAM (or 21 PAPER JAM from Duplex)” on page 608.

SUSPECT COMPONENTS

v Jams only from Auxiliary Tray:– Transport Chute Assembly (Asm-Index: 6-2, page 559)

– MSI No Paper Sensor (Asm-Index: 5-9, page 557)

– MSI No Paper Actuator (Asm-Index: 5-10, page 557)

– Pick Up Solenoid (Asm-Index: 6-17, page 559)

– Pick Up Roll (Asm-Index: 6-9, page 559)

– Retard Pad Assembly (Asm-Index: 6-18, page 559)

– Front Bottom Tray (Asm-Index: 5-5, page 557)

v Jams only from Tray 1:– Cassette No Paper Sensor (Asm-Index: 3-11, page 553)

– Cassette No Paper Actuator (Asm-Index: 3-16, page 553)

– Feed Solenoid (Asm-Index: 4-8, page 555)

– Feed Roll (Asm-Index: 4-1, page 555)

– Feeder Harness (Asm-Index: 3-12, page 553). Use P/N 90H0775.


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)


– 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


– Main Gear Assembly (Asm-Index: 10-10, page 570)

– Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)


Table 17. 21 PAPER JAM


1.

PAPER CONDITIONS AND ADJUSTMENTSv The paper should not be curled, damaged, or damp.v The paper should fit precisely within the guides of the tray cassette. If you

are using the Auxiliary Tray (MSI), the PAPER MENU/AUXSIZE settingmust match the size and orientation (LEF=Long Edge Feed, SEF=ShortEdge Feed).

Are the paper and paper adjustments OK?


2.

PAPER JAM

Clear all paper in the paper path.

Inspect the Registration Actuator (Asm-Index: 7-7, page 562). Also seeTable 58 on page 293.

Is the Registration Actuator operating correctly?

Go to step 3. Repair or replacethe RegistrationActuator(Asm-Index: 7-7,page 562).




3.

DETERMINE WHICH SOURCE(S) ARE INVOLVED WITH THE PAPER JAMv Load all sources with paper.v Switch the printer power ON.v If a jam message is displayed, clear the entire paper path. If an error other

than 21 PAPER JAM occurs, go the appropriate error code procedure.v Set PAPER MENU/TRAYSWITCH=OFF.v During the next steps, record which sources print OK and which sources

are involved with jams. Clear jams as necessary. Note that CONFIGPAGES will try a reprint after the jam is cleared. Press ONLINE to cancel.

v Load Tray 1 (the standard 500 sheet input). Set the PAPERMENU/SOURCE=TRAY 1. Try to print using TEST MENU/CONFIG PAGE. Ifa jam occurs, clear it.

v Load the Auxiliary Tray (the flip-down MSI input at the front of the printer).Ensure that PAPER MENU/ AUXSIZE matches the loaded papersize/orientation. Set PAPER MENU/SOURCE=AUX. Try to print anotherCONFIG PAGE.

v If you have optional Tray 2 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 2.

v If you have optional Tray 3 (500 sheet input or 2000 sheet input) repeat theabove steps for Tray 3.

Did the 21 PAPER JAM ever occur?

Record therelated printsources, and goto step 8

Go to step 4

4.Repeat the above step using TEST MENU/CONTINUOUS TEST. (Stop theContinuous Test with the CANCEL PRINT key; 10 pages may print before theprinter stops.)

Is the printing OK?





5.Did 21 PAPER JAM occur? Record the

related printsources, and goto step 8.

For other errors,return to“Diagnostic QuickPath” on page 28.

6.

DUPLEX UNIT (Asm: 12, page 575)

If a duplex option is not installed, go to step 7.

If a duplex option is installed, set PAPER MENU/DUPLEX=ON. Print usingTEST MENU/CONTINUOUS TEST.

Is duplex printing OK?

Go to step 7 See “Appendix E.Duplex UnitOption” onpage 604. Go tostep 7

7.

PAPER OUT SENSING

From each source, remove all paper. Verify that printing a CONFIG PAGEfrom that source causes an 11 LOAD <size> IN <source> error.

Is the paper out sensing for each source OK?

Possibleintermittent orrandom problems,see page 133

Paper out sensingproblem. (For500-sheet option,replace the500-sheet option)

8.

Use the following chart to determine which step to go to (ignore references tooptions not installed).Aux Tray 1 Tray 2 Tray 3 Go to step:

OK OK bad bad 10OK OK OK bad 10bad OK OK OK 12bad bad bad bad 16OK bad bad bad 9

9.TRAY 1 PRINTING IS BAD

Observe the position of the paper from Tray 1 after the error occurs.

Did the paper start to leave the cassette?

Turn Rollproblem. Go tostep 21.

Pick problem. Goto step 18.




10.

Is the failing Tray a 500 sheet input option?Note: If Tray 2 and Tray 3 printing is bad, Tray 2 is the failing tray.

Go to step 11 The failing tray isthe 2000-SheetInput Drawer. Goto “26 PAPERJAM” onpage 711.

11.

TRAY SPRINGSv Remove the tray (cassette) from the option. Remove the paper.v Press the bottom plate down and ensure that it stays down.v Insert the tray in the option and ensure that the plate springs up.v Inspect the tray for other damage.v If another tray is available, use it for analysis.

Is the tray OK?

Replace the entire500-Sheet inputoption

Replace the tray

12.

FRONT BOTTOM TRAY (Asm-Index: 5-5, page 557)

You are starting analysis for jams only from the AUX Tray.

a. Load paper in the Auxiliary Tray. Set PAPER MENU/SOURCE=AUX andverify PAPER MENU/AUXSIZE. Run a CONFIG PAGE.

b. Inspect the Front Bottom Tray through Front Tray Opening.

Is the Front Bottom Tray raised during printing?





13.

OPERATION OF PICK UP SOLENOID (Asm-Index: 6-17, page 559)

a. Remove the EP cartridge. Close the covers, but leave the Aux Tray openb. Run D50 (see “D50 SOL TRAY A (Auxiliary Tray Feed Solenoid)” on

page 277). From the front of the printer watch for the Aux Pick UpSolenoid try to move the cams at both ends of the shaft on the frontbottom tray. Also, listen for the solenoid to pick.

Does the Pick Up Solenoid operate properly?

Go to step 14 Replace orreassemble theFront Bottom Tray(See page 464)

14.

PICK UP ROLL (Asm-Index: 6-9, page 559) and RETARD PAD ASSEMBLY

a. Run another CONFIG PAGE.b. Inspect the transportation of the paper through Front Tray Opening.

Does the Pick Up Roll transport the paper properly without slipping?

Go to step 15 Replace TransportChute Assembly(See page 468)

15.

ROTATION OF PICK UP GEAR (Asm-Index: 6-15, page 559)

a. Run another CONFIG PAGE.b. Inspect the Pick Up Gear through the narrow opening at the left end of the

EP cartridge (is the cartridge installed?).

Does the Pick Up Gear rotate once during each paper feed?

Clean the Pick UpRoll, Retard PadAssembly, and/orTransport ChuteAssembly

Replace orreassemble parts.

16.REGISTRATION SENSOR

Use “D21 SENSOR TEST” on page 261 to test the Registration Sensor.

Does the Registration Sensor function correctly?

Go to step 17 Go to“RegistrationSensor” onpage 172




17.

The paper jams from Tray 1 and the Aux Tray, but the registration sensor isOK.

Do the tests in step 3 again.

Is there still a problem?

Paper feedproblem

Go to “Intermittentor RandomProblems” onpage 133

18.

TRAY 1 SPRINGS

You are starting analysis for Tray 1 pick problems.

Check Tray 1 (refer to instructions in Step 11).

Is the tray OK?

Go to step 19 Replace the tray

19.

FEED SOLENOID (Asm-Index: 4-8, page 555)

a. Run D51 (see “D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid)” onpage 279).

b. Inspect operation of the Feed Solenoid.

Does the Feed Solenoid operate?

Go to step 20 Go to “FeedSolenoid” onpage 155

20.

FEED GEAR and FEED SOLENOIDa. Run a Test Print (see page 252).

b. Inspect the Feed Solenoid to actuate the Feed Gear.

Does the Feed Solenoid properly actuate the Feed Gear?

Unknown pickproblem from Tray1

Replace the FeedSolenoid (Seepage 446)




21.

CAUTION:<2-35> Remove all watches, rings, jewelry, and other articles(such as a necktie) that may catch on printer parts beforeworking in this area.

TURN ROLL ASSEMBLY (Asm-Index: 4-10, page 555) andREAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555)

You are starting analysis for a Tray 1 turn roll problem.

a. Install the Paper Cassette without the Cassette Cover.b. Run a CONFIG PAGE.c. While the paper is transported, inspect the rolls by opening

the Turn Chute Assembly (Asm-Index: 3-5, page 553) at therear of the printer.

Do the rolls turn?

Mechanicalproblem in papertransport

Go to step 22

22.

ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555)

Run D41 (see “D41 CLUTCH TR (Turn Roll Clutch)” on page 269). You shouldhear a clicking sound when the clutch activates.Note: If you have a 500-Sheet Tray 2, you will hear that clutch activate also.Put your finger on the Turn Roll Shaft near the clutch while activating D41 todetermine if the clutch is activating.

Does the Electromagnetic Clutch function correctly?


Go to step 23

23.ELECTROMAGNETIC CLUTCH (Asm-Index: 4-9, page 555)

Replace the Electromagnetic Clutch (See page 449).



Replace theFeeder PWB (Seepage 420)




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 ifthe paper did not reach the Exit Sensor from the Registration Sensor in the required time.

Action : Clear the jam.Table 18. 23 PAPER JAM


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 Main Gear Assembly (Asm-Index: 10-10, page 570)

v Paper Handling Gear Assembly (Asm-Index: 10-7, page 570)




1. PAPER CONDITIONS

Is the paper loaded in the paper tray wrinkled or damaged?

Replace withfresh, dry paper

Go to step 2




2.

PAPER JAM


Is there any foreign material (such as paper) near the RegistrationActuator?

Remove anyforeign materialNote: Turn theregistration roll byhand to removehard to reachpaper.

Go to step 3

3.

PAPER POSITIONa. If the Duplex Option is installed, remove it.

Note: If paper jams do not occur with the Duplex Option removed, replacethe Duplex Option.

b. Print TEST MENU/CONFIG PAGE until a 23 PAPER JAM occurs.c. Open the Fuser Cover Assembly.d. Open the Fuser Rear Cover (Asm-Index: 8-10, page 564).

e. Inspect the position of paper when the error code 23 PAPER JAM isdisplayed.

Did the paper reach or pass the Exit Actuator (Asm-Index: 8-24, page564)?

The exit sensingmay be bad. Goto step 11.

The paper doesnot reach the exitactuator. Go tostep 4.

4. Did the paper reach the Fuser? Fuser or maingear problem.

Go to step 5

5.

TRANSPORT ASSEMBLY (Asm-Index: 7-1, page 562)

Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) and theRubber Registration Roll (Asm-Index: 7-11, page 562).

Do the Metal Registration Roll and the Rubber Registration Roll rotatesmoothly?

Replace the EPCartridge. If thatdoes not fix theproblem, go tostep 6.

Replace theTransport ChuteAssembly (Seepage 468)




6.

REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570)

Inspect paper position when Error Code 23 PAPER JAM is displayed.

Did the front edge of paper pass between the Metal Registration Roll(Asm-Index: 7-10, page 562) and the Rubber Registration Roll(Asm-Index: 7-11, page 562)?


7.

REGISTRATION CLUTCH ASSEMBLY (Asm-Index: 10-9, page 570)

Use “D43 CLUTCH REG (Registration Clutch)” on page 271 to check theRegistration Clutch Assembly.

Does the Registration Clutch function properly?

Go to step 8 Replace theRegistrationClutch Assembly(See page 495). Ifthe problem stillexists, there is abad MCU PWB orHigh HarnessAssembly.

8.

GEAR RELEASE MECHANISM OF MAIN GEAR ASSEMBLY (Asm-Index:10-10, page 570)

a. Remove the Fuser Assembly (Asm-Index: 8-1, page 564).


Does the Gear Release Mechanism sink down when you open the PopUp Unit, and rise up when you close the Pop Up Unit?

Go to step 9 Replace the MainGear Assembly(See page 497)

9.

ROTATION OF BTR ROLL AND EP CARTRIDGE DRUM

Inspect the position of front edge of the paper.

Did the front edge of the paper pass between the BTR and the Drum?

Go to step 10 Replace the BTRAssembly (Seepage 466), EPCartridge, or theTransport ChuteAssembly (Seepage 468)




10.

There is a paper transport problem between the Registration Sensor and theFuser Exit Sensor. One of the following parts is bad:v Paper Path (check for obstructions)v Main Gear Assembly (Asm-Index: 10-10, page 570)






11.

CAUTION:<2-25> High Temperature; switch off the printer and allow atleast 40 minutes for parts in this area to cool beforehandling.


Replace the Fuser Assembly (See page 487).Note: The Fuser is part of the Usage Kit.



Go to step 12

12.

Use “D21 SENSOR TEST” on page 261 to test the Exit Sensor and circuits(you will need to override the fuser cover switch).

Is the sensing OK?

The paperprobably did notreach the sensorin time. Go tostep 5.

Go to step 13




13.

The Fuser exit sensing is bad, one of the following parts is bad:v High Harness Assembly (Asm-Index: 6-5, page 559)




14.






24 PAPER JAM

Meaning : There is a paper jam between the Paper Cassette / Auxiliary Tray and the Registration Sensor. Thisoften occurs when another paper jam has not been completely cleared. It can also occur if the paper arrivesat the sensor early due to a premature paper pick.

Note: If you were running a pick/feed diagnostic, D50 SOL TRAY A (Auxiliary Tray Feed Solenoid), D51SOLENOID TRAY1 (Tray 1 Feed Solenoid), D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid), or D53SOLENOID TRAY3 (Tray 3 Feed Solenoid), the 24 PAPER JAM may have occurred because asolenoid was pre-picked.


If this action does not fix the problem, go to Table 19 on page 90.




SUSPECT COMPONENTS


v Sensor Problems:– Registration Sensor (Asm-Index: 7-6, page 562)

– Registration Actuator (Asm-Index: 7-7, page 562)

v Early Pick from Auxiliary Tray:– Pick Up Solenoid (Asm-Index: 6-17, page 559)

v Early Pick from Tray 1:– Feed Solenoid (Asm-Index: 4-8, page 555)

v 500-Sheet Paper Tray Option Problems:– 500-Sheet Paper Tray Option: 500-Sheet Feeder (Asm-Index: 20-1, page

697)

v General:– Feeder PWB (Asm-Index: 3-1, page 553)

– MCU PWB (Asm-Index: 12-8, page 575)

– High Harness Assembly (Asm-Index: 6-5, page 559)

– Feeder Harness (Asm-Index: 3-12, page 553) in Asm-Index: 3-6



1.Paper sizes that are not within specifications can cause paper jams (See“Appendix C. Media Specifications” on page 593).

Is the paper size used within specifications?

Go to step 2 Replace withpaper withinspecifications




2.

Switch off printer power, and remove paper from all trays, and then switch onprinter power.

Does the error code appear immediately after switching ON the MainPower?


3.

PAPER JAM


Is there any foreign material (such as paper) touching the RegistrationActuator?

Remove foreignmaterialNote: Turn theregistration roll byhand to removehard to reachpaper.

Return to step 2.

Go to step 4

4.

REGISTRATION SENSOR (Asm-Index: 7-6, page 562)

Use the “D21 SENSOR TEST” on page 261 to check the function of theRegistration Sensor.

Does the Registration Sensor function correctly?

Possibleintermittentregistrationsensing problem,or a dirty sensor.

Go to“RegistrationSensor” onpage 172

5.

DUPLEX UNIT

Does the problem appear only when using the Duplex Unit?

Go to“Appendix E.Duplex UnitOption” onpage 604

Go to step 6




6.

PREMATURE PAPER PICKa. Switch off printer power.b. Add paper to all sources, including the Auxiliary tray.c. Switch on printer power.

Does the error code appear immediately after switching ON the MainPower?

Go to step 7 The error mayhave beencaused by paperthat is now gone.Run TESTMENU/CONFIGPAGE to see ifanother occurs.

7.Is there paper in the paper path? Go to step 8 Go to

“RegistrationSensor” onpage 172

8.Determine which paper sources have the premature paper pick.

Is the problem only with the Auxiliary tray?

Go to “Pick UpSolenoid(Auxiliary Tray)”on page 170

Go to step 9

9.

Does the problem appear when using Tray 2 or 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661 or“Appendix H.2000-Sheet InputDrawer Option” onpage 703

Go to step 10

10. There is a premature feed problem with Tray 1. Go to “Feed Solenoid” onpage 155.




11.






26 PAPER JAM

Meaning : Paper has jammed in the 2000-Sheet Input Drawer exit area.


Error Code Diagnostic Procedure : “26 PAPER JAM” on page 711.

27 PAPER ERROR <source>

Meaning : There is a conflict between the size of paper the printer senses in a Cassette (Tray) and Auxiliarytray and the size of paper that is loaded. This can happen when the printer detects paper that seems too long(including multi-sheet feeds) or too short. This usually occurs because the user fed a size/orientation in theAuxiliary Tray that did not match the PAPER MENU/ AUXSIZE setting.

If CONFIG MENU/AUTOCONTINU=ON, the error message only displays for a short time before doing an″automatic continue″.

Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds. Makesure paper is correctly loaded in the tray and the end guides in the tray are properly set. For the auxiliary tray,verify the AUXSIZE setting on the Paper Menu. You may need to open and close the top cover to clear thecondition.

If this action does not fix the problem, go to Table 20 on page 95.


Table 20. 27 PAPER ERROR <source>


SUSPECT COMPONENTS

v Problems with Tray 1 size sensing:– Feeder PWB (Asm-Index: 3-1, page 553)

– Cassette Guide Assembly L (Asm-Index: 3-6, page 553), includingharness



v Problems with 500-Sheet Paper Tray option size sensing:– Feeder Assembly (Asm-Index: 20-1, page 697)


v Slow paper feeding:– Transport Chute Assembly (Asm-Index: 6-2, page 559)

1. Does the problem appear when printing from Tray 1 or a Tray 2 or a Tray3 option?


2. Does the error message appear when you feed from the Multi SheetInserter (Auxiliary tray)?



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


3.

AUXSIZE SETTING

Check the PAPER MENU/AUXSIZE setting. must match the paper size andorientation (LEF=Long Edge Feed, SEF=Short Edge Feed) of the paper in theAuxiliary tray.

Is the setting OK?

There may be aproblem causingslow paperfeeding from theAuxiliary tray.

Correct theAUXSIZE setting

4.

2000-SHEET INPUT

Does the problem appear when printing from the 2000-Sheet Paper TrayOption?

Go to“Appendix H.2000-Sheet InputDrawer Option” onpage 703

There is aproblem with theEnvelope optionor an intermittentproblem.

5.

PAPER LOADING

Check each paper tray and the paper guide adjustments.

Does each tray have the size guides adjusted to match the loadedpaper?

Go to step 6 Adjust the paperguides

6.

TRAY SIZE SENSINGa. Print TEST MENU/CONFIG PAGE.b. If an error occurs, press CONTINUE.c. On the CONFIG PAGE, under ″Auto Sensed Paper″, compare the sizes

listed to the paper sizes in the trays.

Do the sizes match for all trays?

Go to step 7 Go to “Paper SizeSwitch -500-Sheet PaperTrays” onpage 165

7.

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


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


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 StackActuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator.

When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed onthe operator panel. The printer continues to print a few more pages to clear the paper path before it stops.The 29 OUTPUT FULL message remains until the signals indicate that the paper stack has been removed.

Notes:

1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printerstops after the paper path clears.

2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the user can remove the duplexunit and continue to print simplex jobs.

Action : Remove the output from the bin.

If this action does not fix the problem, go to Table 21.Table 21. 29 OUTPUT FULL


SUSPECT COMPONENTS

v Fuser Assembly (Asm-Index: 8-1, page 564), includes Full Stack Sensor



v If the error only occurs with the Duplex Option, see “29 OUTPUT FULL,with Duplex Installed” on page 610.


Table 21. 29 OUTPUT FULL (continued)


1.PAPER STACK

Is there a paper stack on the Pop Up Cover Assembly close to the FullStack Actuator (Asm-Index: 8-8, page 564)?

Remove paperstack

Go to step 2

2.PAPER CONDITIONS

Is the paper curled?

Replace withfresh dry paper,and go to step 3

Go to step 3

3.

DUPLEX UNIT

Is the printer equipped with a Duplex Unit?

The Full StackSensor on theFuser is disabled.Go to “29OUTPUT FULL,with DuplexInstalled” onpage 610.

Go to step 4

4.

FULL STACK ACTUATOR and SENSOR (Asm-Index: 8-8 and 8-7, page564)

a. Open the Fuser Cover Assembly.b. Push up and then release the Full Stack Actuator.c. Check the actuator and the sensor for correct operation.

Are the actuator and the sensor OK?


5.

FULL STACK SENSOR (Asm-Index: 8-7, page 564)

a. Use “D21 SENSOR TEST” on page 261 to check the Full Stack Sensor.

b. Press and release the Full Stack Actuator (Asm-Index: 8-8, page 564).

Is the sensor OK?

Possibleintermittent orrandom problems,see page 133

Go to step 6


Table 21. 29 OUTPUT FULL (continued)


6.



Replace the Fuser Assembly (See page 487).



Go to step 7

7.

High Harness Assembly (Asm-Index: 6-5, page 559)

v Remove the Controller Assembly (See page 535).

v Disconnect P/J14 from the MCU.v Check the following for continuity:

– J14-8 <=> J142-A1 (at Fuser connection)– J14-7 <=> J142-A2– J14-6 <=> J142-A3

Is there continuity?

Replace the MCU(See page 526)

Replace the HighHarnessAssembly(Asm-Index: 6-5,page 559).Note: Use theremovalprocedure for theTransport ChuteAssembly (Seepage 468)

8.






30 MEMORY OVERFLOW

Meaning : Memory overflow. The printer has received more data than it can fit into its memory. This canhappen when the printer receives too many soft fonts, macros, or complex graphics.

Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds.Otherwise, press the Continue key. Check the current page for errors.

31 MEMORY ALLOC ERROR

Meaning : The printer cannot allocate the memory required to print a job.

Action : If the AUTOCONTINU item in the Config Menu is set to ON, printing resumes in ten seconds.Otherwise, press the Continue key. Check the current page for errors.

32 PRINT OVERRUN

Meaning : A page is too complex to print at the current resolution.

Action : Do one of the following:v If QUALITY is set to 1200, change it to something else (such as 600) and resubmit the job. Use your printer

driver or the Config Menu. The driver setting overrides the menu setting.v If you are feeding paper long-edge first, change it to short-edge first.v Have the customer add more memory.

40 MEMORY OPTION ERROR

Meaning : A SIMM module is not properly seated in its slot or is defective.

Action : Turn off the printer. Remove the controller card. Reseat the SIMM module. If the message recurs afteryou restart the printer, install a new SIMM module.


41 NETWORK OPTION ERROR

Meaning : The printer detected a network interface card in the top slot, but the card is not communicating.

Action : Make sure the network interface card is properly installed and restart the printer. If the same messagerecurs, move the network interface card to the bottom slot and restart the printer. If the message 42NETWORK OPTION ERROR occurs, replace the network interface card. If no message occurs with thenetwork interface card in the bottom slot, replace the Controller.

Remove the network interface card from the printer if you want to print a configuration page or print from theparallel port.


Meaning : The printer detected a network interface card in the bottom slot, but the card is not communicating.

Action : Make sure the network interface card is properly installed and restart the printer. If the same messagerecurs, move the network interface card to the top slot and restart the printer. If the message 41 NETWORKOPTION ERROR occurs, replace the network interface card. If no message occurs with the network interfacecard in the top slot, replace the Controller.

Remove the network interface card from the printer if you want to print a configuration page or print from theparallel port.


43 PS OPTION ERROR

Meaning : The printer has detected a problem with the PostScript section of the Controller SIMM.

Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, perform a cold reset asfollows (this resets all values in printer NVRAM to factory defaults):1. Print a configuration page “Configuration Page” on page 250.

2. Switch off printer power.3. Do the following:

For the LTR (letter) paper group:Press and hold the Online key while switching on printer power. COLD RESET LTR appears in themessage display.For the A4 paper group:Press and hold the Cancel Print key while switching on printer power. COLD RESET A4 appears in themessage display.

If the error recurs, replace the Controller SIMM (See “Controller PWB SIMM” on page 539).

If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).

44 IPDS OPTION ERROR

Meaning : The printer has detected a problem in the IPDS SIMM.

Action : Reinstall the IPDS SIMM. If the message recurs, replace the IPDS SIMM (See “Controller PWBSIMM” on page 539). If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).


45 OPTION ERROR

Meaning : The printer has detected a problem with a SIMM (probably the IPDS SIMM).

Action : Reinstall all SIMMs. If the message recurs, replace the IPDS SIMM (See “Controller PWB SIMM” onpage 539). If the error still recurs, replace the Controller PWB (See “Controller PWB” on page 537).


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

Action : Remove one of the cards.


50 ERROR CALL FOR SERVICE

Meaning : The printer detected a fuser problem.

Action : Turn off the printer for fifteen minutes and then turn on the printer.

If this action does not fix the problem, go to Table 22.Table 22. 50 ERROR CALL FOR SERVICE


SUSPECT COMPONENTS

v Fuser Assembly (Asm-Index: 8-1, page 564)





1.



a. Install a new Fuser Assembly (See page 487).

b. Switch ON the main power. Time how long it takes forREADY or 50 ERROR CALL FOR SERVICE to display.

Does READY appear?


If 50 ERRORCALL FORSERVICE app-eared, go to step2.

For other errorsor messages,return to“Chapter 1.Getting Started”on page 25.

2.Did 50 ERROR CALL FOR SERVICE appear within the first minute? There is a fuser

sensing problem.Go to step 3.

There is a fuserheating problem.Go to step 4.


Table 22. 50 ERROR CALL FOR SERVICE (continued)


3.


HIGH HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)

a. Disconnect P/J14 from the MCU PWB (Asm-Index: 12-8,page 575).

b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564).This will expose J142.

c. Check for the continuity of each wire between:v J14-5 <=> J142-A4 (TEMP)v J14-4 <=> J142-B1 (SG)

Is there continuity between J14 <=> J142?

Replace the MCU(See page 526 or529)

Replace the HighHarnessAssembly

4.

LVPS HARNESS (Asm-Index: 12-14, page 575)

a. Disconnect P/J121 from the LVPS Assembly (Asm-Index: 12-4, page 575)and P/J11 from the MCU PWB (Asm-Index: 12-8, page 575).

b. Check for the continuity of each wire between J11 <=> J121.


Go to step 5 Replace the LVPSHarness




5.


a. Disconnect P/J124 from the LVPS Assembly (Asm-Index: 12-4, page 575).

b. Remove the Fuser Assembly (Asm-Index: 8-1, page 564). This will exposeJ142.

c. Activate the Fuser Cover Switch, and check for continuity between:v P/J124-3 <=> P/J142-3 (AC N)v P/J124-1 <=> P/J142-1 (AC L)


Go to step 6 Replace theFuser CoverSwitch (See page516) or the wiresand connector, orthe High HarnessAssembly (Seepage 521).

6.LVPS ASSEMBLY (Asm-Index: 12-4, page 575)

Replace the LVPS (See page 521).

Problem fixed?


Replace the MCU(See page 526 or529)

7.







Meaning : There is a problem with the ROS (Printhead) Assembly.

Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, go to “Appendix D.Technical Support” on page 602.



Meaning : There is a problem with the ROS (Printhead) Assembly.

Action : Power off the printer, wait twenty seconds, then power on.



SUSPECT COMPONENTS

v POP-UP/ROS Assembly (Asm-Index: 11-20, page 572)

v CRU Sensor Assembly (Asm-Index: 11-15, page 572)



1.

CRU SENSOR ASSEMBLY (Asm-Index: 11-15, page 572)Note: The CRU Sensor Assembly has a switch to detect the presence of theEP cartridge and an LD switch that disables the ROS Laser Diode when thecartridge is removed.

a. Run “D21 SENSOR TEST” on page 261 to test the CRU sensor andcircuits.Note: Test D21 does not test the LD switch.


Is sensing OK?

Go to step 2 Replace the CRUSensor Assembly,which includesthe Harness (Seepage 503)

2.Remove the controller, and verify that connector P/J12 (ROS) at the MCU isOK.

Are the connectors OK?





3.

DANGER

<1-16> The following procedures require that you workwith power on. Follow the instructions under “Workingwith Power On” in Electrical Safety for IBM CustomerEngineers , S229-8124. Do not touch moving parts.

LASER DIODE POWERa. Unplug P/J12.b. Install the EP Cartridge (Asm-Index: 11-40, page 572).

c. Close the Pop Up Unit.d. Check the voltage between P12-7 (5VDC-LD)<=> P12-6

(SG) on the MCU PWB (Asm-Index: 12-8, page 575).

Is there +5 VDC between P12-7 <=> P12-6?

Go to step 4 Replace the MCUPWB (See page526 or 529), orthe LVPSAssembly (Seepage 521).

4.

DANGER


LASER DIODE POWER SUPPLY OF ROS ASSEMBLY(Asm-Index: 11-20, page 572)

Check the voltage between P12-2 <=> P12-6.

Is there 5VDC between P12-2 <=> P12-6?





5.

CONTINUITY ON MCU PWB

Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).

Check for the continuity between P11-2 <=> P12-1.

Is there continuity between P11-2 <=> P12-1?

Replace the LVPSAssembly (Seepage 521), or theLVPS Harness.


6.

DANGER


SOS POWER SUPPLY OF ROS ASSEMBLY (Asm-Index:11-20, page 572)

a. Disconnect P/J15.b. Check the voltage between P/J12-10 <=> P/J12-8.

Is there 5VDC between P/J12-10 <=> P/J12-8?

Go to step 7 LVPS problem, goto “LVPS” onpage 163.




7.

DANGER


SCANNER ASSEMBLY POWER SUPPLY

Check the voltage between P12-15 <=> P12-14.



8.

CONTINUITY ON MCU PWBa. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).

b. Check for the continuity between P12-15 <=> P21-1.


Go to “24V PowerSupply to MCU”on page 144





9.

DANGER


SCANNER MOTOR ON SIGNALa. Switch OFF the Main Power.b. Leave P/J15 disconnected.c. As you switch on the power in the next step, observe the

voltage between P/J12-13 <=> P/J12-14.d. Switch ON the Main Power.

Is there 4.1VDC between P/J12-13 <=> P/J12-14 when youswitch on the Main Power?

Go to step 10 Replace the MCUPWB (See page526 or 529)

10.







Meaning : There is a problem with the Main Motor.




SUSPECT COMPONENTS

v Main Motor (Asm-Index: 10-6, page 570)






v Feeder Assembly (Asm-Index: 20-1, page 697)


v Rear Roll Assembly (Asm-Index: 4-11, page 555)

v Turn Roll Assembly (Asm-Index: 4-10, page 555)

v Feed Shaft Assembly (Asm-Index: 4-2, page 555)

Note: The Main Motor runs when the printer power is switched on, and stopsafter the fuser reaches operating temperature.




1.

MAIN MOTOR START (Asm-Index: 10-6, page 570)

a. Switch off printer power.b. Remove the Controller Assembly (See page 535).

c. Close all interlocksd. Switch on printer power.

Does the Main Motor start or try to start?


2.

MAIN MOTOR (Asm-Index: 10-6, page 570)

Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually. The magnets in the Main Motor will cause pulsing resistance.

Does the Main Motor rotate smoothly without binding?


3.

TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559)

a. Open the Pop Up Unit.b. Remove the EP Cartridge (Asm-Index: 11-40, page 572).

c. Rotate the Metal Registration Roll (Asm-Index: 7-10, page 562) andRubber Registration Roll (Asm-Index: 7-11, page 562) manually, turning thegears at the end of the metal roll.

Do the Metal Registration Roll and Rubber Registration Roll rotatesmoothly?

Go to step 4 Replace theTransport ChuteAssembly (Seepage 468)

4.

REAR ROLL ASSEMBLY (Asm-Index: 4-11, page 555) and TURN ROLLASSEMBLY (Asm-Index: 4-10, page 555)

a. Open the Turn Chute Assembly.b. Rotate the Rear Roll and the Turn Roll manually.

Do the Rear Roll and the Turn Roll rotate smoothly?

Go to step 5 Replace the RearRoll Assembly(See page 453) orthe Turn RollAssembly (Seepage 451)




5.

PICK UP ROLL ASSEMBLY (Asm-Index: 6-8, page 559)

a. Press down the Armature of the Pick Up Solenoid (Asm-Index: 6-17, page559).

b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570) clockwisemanually.

Does the Pick Up Roll Assembly rotate smoothly?


6.

FEED SHAFT ASSEMBLY (Asm-Index: 4-2, page 555)

a. Press down the armature of the Feed Solenoid (Asm-Index: 4-8, page555).Note: The Feed Solenoid is located behind the MCU PWB, near the lowerleft corner.


c. Inspect the rotation of the Feed Gear (Asm-Index: 4-5, page 555).

Does the Feed Gear rotate smoothly?

Go to step 12 Replace Gears,etc. which maydisturb therotation (Seepage 438, 442, or446)

7.

EP CARTRIDGE (Asm-Index: 11-40, page 572)

a. Remove EP Cartridge.b. Rotate the rotor of Main Motor (Asm-Index: 10-6, page 570) clockwise

manually.

Does the rotor of Main Motor rotate smoothly?

Replace the EPCartridge(Asm-Index:11-40, page 572)

Go to step 8




8.



a. Remove the Fuser Assembly (See page 487).

b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page570) clockwise manually.

Does the rotor of the Main Motor rotate smoothly?

Replace theFuser Assembly(See page 487)

Go to step 9

9.

FEEDER ASSEMBLY (Asm-Index: 20-1, page 697)

a. Remove the Out Idler Gear (Asm-Index: 4-16, page 555).



Replace theFeeder Assembly(See page 666)

Go to step 10

10.

PAPER HANDLING GEAR ASSEMBLY (Asm-Index: 10-7, page 570)

a. Remove the Paper Handling Gear Assembly (See page 492).

b. Rotate the rotor of the Main Motor (Asm-Index: 10-6, page 570).


Replace thePaper HandlingGear Assembly(See page 492).

Go to step 11

11.

MAIN MOTOR (Asm-Index: 10-6, page 570)

a. Remove the Main Motor from the printer frame (See page 489).

b. Rotate the rotor of the Main Motor.


Replace the MainGear Assembly(Asm-Index:10-10, page 570).

Replace the MainMotor (See page489).




12.

MAIN MOTOR HARNESSa. Disconnect P/J16 from the MCU PWB (Asm-Index: 12-8, page 575).

b. Check the resistance between J16-1 <=> J16-2.

Is there approximately 14 K ohms between J16-1 <=> J16-2?

Replace the MainMotor (See page489), or the MCUPWB (See page526 or 529)

Replace the MainMotor (See page489)

13.







Meaning : The printer has detected a problem in the duplex unit.

Action : Make sure the duplex unit is installed correctly. If the problem continues, suspect the followingcomponents:v Duplex Unit (Asm-Index: 30-1, page 652)

v Controller PWB (Asm-Index: 13-6, page 578)

v MCU PWB(Asm-Index: 12-8, page 578)



Meaning : The Fan is not rotating. The Fan rotates at Low Speed when printer power is switched on. The Fanrotates at High Speed when the Main Motor is switched on.

Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs.



1.

SUSPECT COMPONENTSv Fan (Asm-Index: 12-3, page 575)




Inspect the fan. Is it OK?

Go to step 2 Replace the Fan(See page 518)

2.

FAN (Asm-Index: 12-3, page 575)

Replace the Fan (See page 518).



See “MCU ⇔LVPS ⇔INTERLOCKSWITCH andFANs” onpage 311, or runD23 (see “D23TEST FAN” onpage 267).




3.







Meaning : There is problem with NVRAM in the MCU.




SUSPECT COMPONENTS


1.

Switch the printer power off, then on. If using Letter size paper, press ONLINEduring printer power-up. If using A4 size paper, press CANCEL during printerpower-up.Note: If the printer powers on without error, print a CONFIG PAGE.

Does the printer become READY?

Problem fixed, orpossibleintermittent orrandom problems(See page 133)

Go to step 2

2. Does the 56 ERROR CALL FOR SERVICE appear?Replace the MCU(See page 526)

Go to “Chapter 1.Getting Started”on page 25

3.







Meaning : The printer has detected an error in the Controller SIMM checksum.







Meaning : The printer has detected an error in the DRAM.

Action : Power off the printer, wait twenty seconds, then power on. If the error recurs, reinstall all SIMMs.

If the message recurs, replace the DRAM SIMM (See “Controller PWB SIMM” on page 539).




Meaning : The printer has detected an error in the NVRAM (EEPROM).






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




73 DISK ERROR



80 ADD MEMORY FOR IPDS

Meaning : The printer requires more memory before it can process IPDS jobs.

Action : Have the customer install more memory.

80 ADD MEMORY FOR PAGES, ESC/P

Meaning : The printer requires more memory before it can process PAGES and ESC/P jobs

Action : Have the customer install more memory.

81 INSUFFICIENT MEMORY FOR IPDS

Meaning : The printer does not have enough memory to process IPDS jobs.

Action : Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the errorrecurs, the customer may need to install more memory.

81 INSUFFICIENT MEMORY FOR PAGES

Meaning : The printer does not have enough memory available to process PAGES, ESC/P jobs.

Action : Power off the printer, wait twenty seconds, and then power on the printer to clear memory. If the errorrecurs, the customer may need to install more memory.


82 HOST TIMEOUT

Meaning : The coax network interface card has sent an Intervention Required message to the host. This erroroccurs when (a) the printer is OFFLINE for longer than the HLD TMEOUT setting in the Coax Setup Menu, or(b) the printer has been in an intervention required state (such as out of paper) for longer than the IRQTMEOUT setting.

Action : Solve the problem that caused the message (for example, press the Online key to put the printeronline, or add paper). To disable this error message, set the HLD TMEOUT and IRQ TMEOUT values in theCoax Setup Menu to 0.

83 CX SEND STATE

Meaning : Your coax host has placed your printer in “Send State” and is waiting for the printer to return a PAsignal.

Action : Press the Continue key to clear the message. (You may need to press the key more than once.)Then do the following to send the PA signal.1. Press the Online key to take the printer offline.2. Press the Menu key until you see the Coax SCS Menu.3. Press the Item key until you see PA1 or PA2 (whichever signal you want to send).4. Press the Enter key to send the signal.5. Press the Online key to resume printing.

84 NO FONT SIMM FOR PAGES, ESC/P

Meaning : The printer has detected that Japanese Heisei font SIMM is not installed.

Action : Power off the printer, install a Japanese Heisei font SIMM, and then power on the printer.


Printer Problems without Error CodesFuse or Power Problem

The fan does not rotate, the motors never turn on, and the operator panel is blank. The printer does notfunction.


Table 27. Fuse or Power Problem


SUSPECT COMPONENTS



v Interlock Switch (Asm-Index: 12-1, page 575)

v Fan (Asm-Index: 12-3, page 575)

v Console Assembly (Asm-Index: 1-18, page 548)

v ROS Assembly (Asm-Index: 11-20, page 572)


v MSI No Paper Sensor (Asm-Index: 5-9, page 557)


v HVPS (Asm-Index: 12-11, page 575)

v Main Motor (Asm-Index: 10-6, page 570)

v CRU Sensor Assembly (Asm-Index: 11-15, page 572)


v Feeder PWB (Asm-Index: 3-1, page 553)

v Feed Solenoid (Asm-Index: 4-8, page 555)

v Electromagnetic Clutch (Asm-Index: 4-9, page 555)

v Cassette No Paper Sensor (Asm-Index: 3-11, page 553)


Table 27. Fuse or Power Problem (continued)


1.

AC POWER CORD

Plug the AC Power Cord into the back of the printer, and the other end into anAC wall outlet.Note: If there is a 2000-Sheet Paper Tray Option installed, there are twopower cords and two power switches. One cord connects the option to thewall outlet, and the other connects the option to the printer. AC power ispresent at both machines even when both power switches are turned off.

Switch on the power switches.

Does the problem still exist?

Go to step 2 Verify the fix. Alsoverify that theproblem jobprints.Note: If there is adifferent symptom,go to “Chapter 1.Getting Started”on page 25.

2.

AC POWER

Check the voltage at the AC wall outlet. The acceptable voltage ranges are:v Low voltage: 100–127 V acv High voltage: 220–240 V ac

Is the measured voltage OK?

Go to step 3 Notify customer ortheir electrician.

3.

CONTROLLERa. Remove the Controller Assembly (See page 535).

b. Switch ON the Main Power.c. Observe the Fan (Asm-Index: 12-3, page 575).

Does the Fan rotate?

There is aproblem with thecontroller, acontroller option,or the console.

Go to step 4




4.

LVPS OR LVPS FUSE (Asm-Index: 12-4, page 575)

a. Remove the LVPS Assembly (See page 521).

b. Remove the fuse, located near the power switch.c. Check the continuity of the fuse.

Is the fuse OK?

Replace the LVPSAssembly (Seepage 521)

Go to step 5

5.

LVPS FUSE

Blown fuse. This can be caused by a defective LVPS, a defective FRUconnected to the LVPS, or an overcurrent condition that no longer exists.a. Install a new fuse (10A). If a fuse is not available, install a new LVPS.b. Disconnect P/J11 from the MCU Assembly. Ensure that the fan is

connected to the LVPS (P/J122).


The fuse is OK.There may beanother problemthat blew theoriginal fuse. Goto step 6.

Go to step 7

6.

MCU CIRCUITSa. Connect P/J11.b. Switch on the printer power.


The blown fusewas the problem.If the fuse blowsagain later, go tostep 7.

The fuse blewagain. One of theMCU loads iscausing aproblem. Obtainmore fuses, anddiagnose bysequentiallyconnecting theconnectors listedin step 7.




7.

LVPS (Asm-Index: 12-4, page 575)

Replace the LVPS Assembly (See page 521)

Other components that can blow the fuse:

v At the LVPS:– P/J122: to the fan

v At the MCU:– P/J11: to the LVPS (and all of the following)– P/J12: to the ROS Assembly– P/J13: to the Registration Clutch, Registration Sensor, No Paper Sensor

and Pick Up Solenoid– P/J14: to the Fuser Assembly– P/J15: to the HVPS– P/J16: to the Main Motor– P/J18: to the Interface PWB or to Fuser Cover Switch– P/J19: to the Console Panel– P/J20: to the Feeder PWB– P/J31: to the Controller Assembly– Controller, Controller option, or console.




8.






Intermittent or Random Problems

Gather as much information as possible (see “Defining the Problem” on page 26). Closely inspect thesuspected area, assembly, or part.

You will be directed to these diagnostics from the Diagnostic Quick Path for problems that do not post an errorcode.

Check the following:

1. Is the printer plugged into a recommended AC outlet?2. Is the AC power at the outlet within specifications?3. Is the AC power cord connected to the printer?4. Is the AC power cord in good condition; not frayed or broken?5. Is the printer grounded through the AC outlet?6. Is recommended paper stock used in the printer?7. Is the printer in an area where the temperature and humidity are moderate and stable?8. Is the printer in an area that is free of dust?9. Is the printer in an area away from water outlets, steamers, electric heaters, volatile gases, or open

flames?10. Is the printer shielded from the direct rays of the sun?11. Does the printer have recommended space around all sides for ventilation?12. Is the printer on a level and stable surface?13. Does the customer use the printer as instructed in the customer documentation?14. Are consumables, such as the EP Cartridge, replaced at recommended intervals?

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


If you do not resolve the problem, return to “Diagnostic Quick Path” on page 28 and define the problem againor call 1–800–358–6661 for technical support.

If you exchange a part and the problem is not fixed, reinstall the original part.

Check the following:

v Disconnect and reseat connectors in the associated area.v Check for loose, worn, or broken connectors and cables.v Check the environment, such as ambient temperature and humidity.v Check for RF noise such as a radio or TV transmitter.


Operator Panel, Controller, and Power Problems

Use this diagnostic to solve problems which involve a blank or inoperative operator panel, light or darkrectangles displayed in operator panel, and power problems.Table 28. Operator Panel, Controller, and Power Problems


SUSPECT COMPONENTS

v DRAM SIMM (Asm-Index: 100-14∼17, page 585)

v Controller SIMM (Asm-Index: 100-4, page 585)

v Controller PWB (Asm-Index: 13-6, page 578)





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


The following should happen at a normal power-up (no network cards, noerrors):

1. IBM INFOPRINT 20 displays soon after the power is switched on.2. The fan turns at low speed.3. The motor turns, causing the exit rolls to move (whenever the motor

turns, the fan runs at high speed).4. All LEDs momentarily turn on and WARMING UP... displays after

approximately 12 seconds.5. The motor stops.6. WARMING UP... continues to display until the fuser warms up (can last

longer than 1 minute if the printer is cold).7. The ONLINE LED blinks.8. After the fuser warms up, the ONLINE LED stays on and READY

displays on the LCD (if a NIC card is installed, I/O INITIALIZING maydisplay for several minutes).

9. Pressing the ONLINE key causes the printer to go off-line. (OFFLINEdisplays on the LED and the ONLINE LED is off.)

10. Menu/item/value keys allow menu navigation.

Note: The Controller must have at least 1 DRAM memory SIMM installed (inthe group of 3 sockets). Since there is no DRAM built into the controller, theController cannot operate without a DRAM SIMM. The symptom with noDRAM is light, solid rectangles on the top line of the display. After severalminutes, unrequested blank pages, or pages with black stripes may print.




1.

Switch on the printer power and wait 5 minutes to ensure that the symptomdoes not change. Look for light, solid rectangles on the top line of the display.These rectangles may be very light; switch off printer power and compare toensure that you do have these rectangles when the printer is switched on.

Is the symptom solid rectangles on the top line of the display?


2.

SIMMsa. Reseat the Controller SIMM (OS, PCL, and PS).b. Reseat 1 DRAM SIMM.c. Remove the Controller options, if installed (second DRAM SIMM, third

DRAM SIMM, IPDS SIMM, flash memory SIMM, and the hard drive).


Reinstall theController optionSIMMS, one at atime, to determinewhich fails.

Go to step 3

3.

DRAM SIMM

Move the DRAM SIMM to another socket within the group of 3 sockets.


If the userrequires 3 DRAMsockets, replacethe ControllerPWB (See“Controller PWB”on page 537).

Go to step 4

4.If the printer had only 1 DRAM SIMM, replace the SIMM (see “Controller PWBSIMM” on page 539).


The DRAM SIMMwas bad

Go to step 5




5.

Replace the Controller SIMM (See “Controller PWB SIMM” on page 539).


The ControllerSIMM was bad

The ControllerPWB is probablybad. Run Test“Printing a TestMatrix PageWithout theController” onpage 252 to verifythat the problemis the Controllerand not the MCU.

6.

Is the symptom a continuous I/O INITIALIZING message? Go to “Ethernet /Token-Ring NICPrintingProblems” onpage 150

Go to step 7

7. Is the symptom a continuous WARMING UP or a continuous IBMINFOPRINT 20 message?





8.

Solid rectangles usually indicate a controller problem, and WARMING UP... orIBM INFOPRINT 20 being displayed usually indicates an MCU problem. Testthe MCU by performing “Printing a Test Matrix Page Without the Controller” onpage 252.

Do the test pages print OK?

The MCU isfunctioningcorrectly. Replacethe ControllerSIMM (See“Controller PWBSIMM” onpage 539). If theproblem stillexists, replace theController PWB(See “ControllerPWB” onpage 537).

Go to step 9

9.

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

Do the test pages print OK?

The MCU isfunctioningcorrectly. Replacethe ControllerSIMM (See“Controller PWBSIMM” onpage 539). If theproblem stillexists, replace theController PWB(See “ControllerPWB” onpage 537).

Bad MCU or 5Vpower problem.Go to “LVPS” onpage 163.




10.Ensure that there are no paper jams, and that all covers are closed. Switch offthe printer power, then switch it back on.

Do both the fan and motor activate?


11.CONSOLE/OPERATOR PANEL

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 theconnections seem OK, replace the console assembly (See page 418).



Go to step 13

13.

There is a problem with one of the following components:v Console Harness (Asm-Index: 13-6, page 578)

v Controller Harness (Asm-Index: 13-8, page 578)


14.When Online is pressed, the Online LED should turn off. The other keyscontrol menus.

Do the keys function correctly?


Go to step 12

15. Does the fan turn on? Go to “LVPS” onpage 163

Go to “Fuse orPower Problem”on page 127




16.






Toner Low and No Error Code 02 Displayed

02 is not displayed when the EP Cartridge is empty.Table 29. 02 Not Displayed


SUSPECT COMPONENTS





v Toner Sensor Harness (Asm-Index: 5-17, page 557)


1.


a. Run a Test Print.b. Inspect the print quality.

Does the print appear light due to an empty EP Cartridge?

Go to step 2 Problem does notexist.

2.

TONER SENSOR (Asm-Index: 5-14, page 557)

a. Use “D21 SENSOR TEST” on page 261 to check the function of the TonerSensor.Note: Activate the sensor with a non-magnetized piece of steel.

Does the Toner Sensor function correctly?

Go to step 3 Go to “TonerSensor” onpage 176


Table 29. 02 Not Displayed (continued)


3.






Other DiagnosticsThese are secondary diagnostics branched to by other diagnostics.

24V Power Supply to MCUTable 30. 24V Power Supply to MCU


SUSPECT COMPONENTS


v CRU Guide Assembly L (Asm-Index: 11-30, page 572)

v CRU Guide Assembly R (Asm-Index: 11-31, page 572)





v Heater Assembly (Asm-Index: 9-5, page 567)



1.

HARNESSa. Remove the Controller Assembly (See page 535).

b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575) andP/J123 from the LVPS Assembly (Asm-Index: 12-4, page 575).

c. Close the Pop Up Unit.d. Check for the continuity between J21-1 <=> J123.


Go to step 2 Replace theInterlock Switch(See page 513)


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


2.

DANGER


LVPS ASSEMBLYa. Disconnect P/J126.b. Switch ON the Main Power.c. Check the voltage between J123 <=> J126-2.

Is there 24VDC between J123 <=> J126-2?

Go to step 3 Replace the LVPSAssembly (Seepage 521)

3.






Electrical NoiseTable 31. Electrical Noise


SUSPECT COMPONENTS








v Heater Assembly (Asm-Index: 9-5, page 567)



1.

EXTERNAL NOISEa. Check if there is other electrical equipment, such as electrical generators,

radio transmitters, or devices using electrical motors, within ten feet of theprinter.

b. Shut off the other electrical equipment, or relocate the printer at leasttwenty feet away from other devices.

Is the Electrical Noise problem still present?


2.AC GROUND

Check the AC wall outlet.

Is the AC wall outlet correctly wired and grounded?

Go to step 3 Have thecustomer repairthe AC wall outlet


Table 31. Electrical Noise (continued)


3.EP CARTRIDGE

Replace the EP Cartridge.

Is the Electrical Noise problem still present?


4.


Inspect the grounding screw for the cable connected to the Main PowerSwitch.

Is the cable grounded properly?

Go to step 5 Attach thegrounding screwproperly

5.

CRU GUIDE ASSEMBLY L (Asm-Index: 11-30, page 572)

a. Install the EP Cartridge.b. Inspect the spring contact on the CRU Guide Assembly L with the plate

terminals on the EP Cartridge.

Is the spring clean and does it contact the plate properly?

Go to step 6 Replace the CRUGuide Assembly L(See page 506)

6.

CRU GUIDE ASSEMBLY R (Asm-Index: 11-31, page 572)

a. Remove the EP Cartridge.b. Inspect the ground spring on the rear end of the CRU Guide Assembly R

(Asm-Index: 11-31, page 572).

Is the ground spring intact free of contamination and deformation?

Go to step 7 Clean the groundspring or replacethe CRU GuideAssembly R (Seepage 510)

7.

TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559)

a. Remove the Transport Chute Assembly (See page 468).

b. Check for the continuity on all the wires in the Transport Chute Assembly.

Is there continuity on all the wires?





8.

DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page559)

Inspect the DTS and the TR wires.

Are the wires connected properly?

Go to step 9 Connect the wiresproperly.

9.


HEATER ASSEMBLY (Asm-Index: 9-5, page 567)

Inspect the cables of P142-1 and the right end of the HeaterRod.

Are the cables attached properly?

Go to step 10 Attach the cablesproperly

10.

HVPSa. Remove the Controller Assembly (See page 535).

b. Disconnect P/J15 from the MCU PWB (Asm-Index: 12-8, page 575).

c. Run a Test Print (continuously approximately ten sheets).

Do the Test Prints run normally?

Replace theHVPS (See page532)

Go to step 11

11.Replace the MCU PWB (See page 526 or 529)

Is the problem still present?


12.Inspect all of the grounds in the printer.

Are the grounds proper?

Replace theSuspectComponents

Repair the badgrounds




13.






Ethernet / Token-Ring NIC Printing Problems

Note: If the network interface card is installed, but not connected to the LAN, a page with network interfacecard details will be printed. You can also print this page from the Test Menu.

Table 32. Ethernet/Token-Ring NIC Printing Problems


1.Is the problem only with IPDS jobs?Note: To answer this questions, you may need to ask the SystemAdministrator to send a PCL or PS job.


2.

Print a Config Page (see “Configuration Page” on page 250).

Is IPDS indicated on the Config Page?

There is probablya configurationproblem. Referthe SystemAdminstrator to“Ethernet andToken Ring QuickConfigurationGuide”,G544-5499.

Reseat the IPDSSIMM. If thatdoes not fix theproblem, install anew IPDS SIMM.

3.

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

Does READY appear within 5 minutes?

Go to step 4 Return to“Diagnostic QuickPath” on page 28with the new errorcode or symptom.


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


4.

If a NIC configuration page prints approximately 2 minutes after power isswitched on, the NIC is working correctly. But there is probably a problem inthe LAN connection for that NIC.

Did a NIC Configuration page print for each installed NIC?Note: If your printer has both Ethernet and a token ring NIC, determine whichNIC configuration page printed. A NIC configuration page will be printed for aNIC that has a LAN connection problem.

The printer andNIC are OK.

If the problem stillexists, problems,there is probablya LAN cable orLAN configurationproblem.

Refer the SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.

Go to step 5

5.

Try to print a configuration page for the printer (not a NIC configuration page)using TEST MENU/CONFIG PAGE.

Does the TEST MENU/CONFIG PAGE print?

Verify that eachNetwork InterfaceCard has aunique IPaddress. Go tostep 6

Return to“Chapter 1.Getting Started”on page 25 with

the new errorcode or symptom.

6. Look at the printer configuration page. Is each installed NIC indicated onthe printer configuration page?


7. Can you print a NIC Config Page for each installed NIC from the printer(TEST MENU/PRINT EN CONFIG or TEST MENU/PRINT TR CONFIG)?





8.

The printer and NIC seem OK.

Check the LEDs on the back of the NIC; they should be as follows:v Token ring

RING NSRT = ONSPD ERROR = OFF

v EthernetUTP (10base-T) LINK = on and NET ACT = on (flashes intermittently)BNC (10base2) LINK = off and NET ACT = on (flashes intermittently)

Do the LEDs match the ″properly connected ″ definition?

The printer, NIC,and LANconnection seemOK.

Suspect a job orconfigurationproblem. Referthe SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.

There is a LANcablingconfigurationproblem. Referthe SystemAdminstrator to“Ethernet andToken RingConfigurationGuide”,G544-5240.

9.

The NIC that is not shown on the printer configuration page, or the Controllerhas a problem.v Power off.v Reseat the NIC.v Power on and wait for 5 minutes.



Go to step 10




10.

Reset the NIC jumpers as follows:a. Switch off printer power.b. Remove the NIC.c. Move jumper JX1 to the RST (reset) position.d. Reinstall the NIC.e. Switch on printer power and wait until READY displays.f. Switch off printer power.g. Move jumper JX1 to the original position.h. Reinstall the NIC.



If there is onlyone NIC in theprinter, go to step11. If you haveanother NIC, youcan try swappingNIC positions onthe controller toisolate NIC vsController.

11.

Install a new NIC.



Replace theController SIMM(see “ControllerPWB” onpage 537) or theController PWB(See “ControllerPWB” onpage 537)




12.






Feed SolenoidTable 33. Feed Solenoid


SUSPECT COMPONENTS

v Feed Solenoid (Asm-Index: 4-8, page 555)



v Cassette Guide Assembly L (Asm-Index: 3-6, page 553), including theFeeder Harness (Asm-Index: 3-12, page 553)


1.

DANGER


FEED SOLENOID POWER SUPPLYa. Remove the Controller Assembly (See page 535)

b. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).

c. Check the voltage between P/J20-A11 <=> P/J20-B1.

Is there 24VDC between P20-A11 <=> P20-B1?



Table 33. Feed Solenoid (continued)


2.

CONTINUITY ON MCU PWB (Asm-Index: 12-8, page 575)

a. Disconnect P/J21 from the MCU PWB.b. Check for the continuity between P13-9 <=> P21-1.




3.

Does the problem appear when using Tray 2 or 3? Go to“Appendix G.500-Sheet PaperTray Option” onpage 661, or“Appendix H.2000-Sheet InputDrawer Option” onpage 703.

Go to step 4

4.

FEEDER PWB (Asm-Index: 3-1, page 553)

a. Disconnect P/J201, P/J202 and P/J203 from the Feeder PWB (Asm-Index:3-1, page 553).

b. Check for the continuity between P201 <=> P202 <=> P203 below:v P201-A1 <=> P202-A1 <=> P203-8v P201-A8 <=> P203-9

Is the continuity on wires above between P201 <=> P202 <=> P203?

Go to step 5 Replace theFeeder PWB (Seepage 420)

5.

PICK UP SOLENOID (Asm-Index: 6-17, page 559)

a. Leave P/J203 disconnected.b. Check the resistance between J203-8 <=> J203-9.

Is there approximately 120 ohms resistance between J203-8 <=> P203-9?





6.

FEEDER HARNESS (Asm-Index: 3-12, page 553)

a. Leave P/J203 disconnected and disconnect P/J204 from the FeedSolenoid (Asm-Index: 4-8, page 555).

b. Check for the continuity on wires between J203-8 <=> J204-2 and J203-9<=> J204-1.

Is there continuity on both wires?

Replace the FeedSolenoid (Seepage 446)

Replace theFeeder Harness

7.

TRAY HARNESS (Asm-Index: 12-17, page 575)

a. Leave P/J20 disconnected.b. Check for the continuity on wires between J20 <=> P201 of the Tray

Harness below:v J20-A10 <=> J201-A1v J20-A4 <=> J201-A8

Is there continuity on wires above between J20 <=> P201?

Go to step 8 Replace the TrayHarness




8.

DANGER


FEEDER PWB (Asm-Index: 3-1, page 553)

a. Disconnect P/J12, P/J15 and P/J17 from the MCU PWB(Asm-Index: 12-8, page 575).

b. Check the voltage between P203-8 <=> P/J20-B1 andP203-9 <=> P/J20-B1.

Is there 24VDC between P203-8 <=> P/J20-B1 and P203-9<=> P/J20-B1?


Replace theFeeder PWB (Seepage 420)

9.






HVPSTable 34. HVPS


SUSPECT COMPONENTS






v HVPS Harness (Asm-Index: 12-15, page 575)



1.

CRU GUIDE ASSEMBLY L POWER SUPPLYa. Ensure that an EP Cartridge is installed.b. Inspect Spring contact on the CRU Guide Assembly L and the plate

terminals on the EP Cartridge.

Are the Spring contacting the plate terminals properly?

Go to step 2 Replace the CRUGuide Assembly L(See page 506)

2.

CRU GUIDE ASSEMBLY L POWER SUPPLYa. Remove the HVPS (See page 532) while performing next step.

b. Inspect the Spring contact on the CRU Guide Assembly L and the HVPSduring the removal of the HVPS.

Does the Spring contact the HVPS properly?

Go to step 3 Replace the CRUGuide Assembly L(See page 506).


Table 34. HVPS (continued)


3.

CRU GUIDE ASSEMBLY R METAL GROUNDING PLATEa. Remove the EP Cartridge (Asm-Index: 11-40, page 572).

b. Inspect the Metal Grounding Plate on the rear end of the CRU GuideAssembly R (Asm-Index: 11-31, page 572).

Is the Metal Grounding Plate intact, free of contamination, deformation ordamage?

Go to step 4 Replace the CRUGuide AssemblyR (See page 510)

4.

HVPS HARNESS ASSEMBLY (Asm-Index: 6-5, page 559)


b. Disconnect P/J15 and P/J151 from the MCU PWB and HVPS.c. Check for the continuity between J15 <=> J155 as below:v J15-1 <=> J151-13v J15-8 <=> J151-6v J15-2 <=> J151-12v J15-9 <=> J151-5v J15-3 <=> J151-11v J15-10 <=> J151-4v J15-4 <=> J151-10v J15-11 <=> J151-3v J15-5 <=> J151-9v J15-12 <=> J151-2v J15-6 <=> J151-8v J15-13 <=> J151-1v J15-7 <=> J151-7


Go to step 5 Replace theHVPS Harness




5.

DANGER


24VDCa. Switch ON the Main Power.b. Check the voltage between P15-1 and the Printer Frame.

Is the voltage between P15-1 and the Printer Frame 24VDC?


6.

MCU PWB (Asm-Index: 12-8, page 575)

a. Switch OFF the Main Power.b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).

c. Check for the continuity between P21-1 <=> P15-1.




7.Replace the MCU PWB (See page 526 or 529)

Does the problem still appear?


8.Replace the HVPS (See page 532)

Does the problem still appear?





9.

DTS and TR WIRES of the High Harness Assembly (Asm-Index: 6-5, page559)

a. Remove the Transport Chute Assembly (See page 468)

b. Disconnect the DTS and TR Plugs from the HVPS (Asm-Index: 12-11,page 575) and from the Transport Chute Assembly.

c. Check for the continuity between both ends of the DTS and TR wires.

Is there continuity through the DTS and TR wires?

Call technicalsupport (see“Appendix D.TechnicalSupport” onpage 602).

Replace the wiresthat do not havecontinuity (DTS orTR) that arecontained in theHigh HarnessAssembly (Seepage 468 for theremovalprocedure)

10.






LVPSTable 35. LVPS


SUSPECT COMPONENTS




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?

Go to step 2 Replace the LVPSAssembly (Seepage 521)

2.

LVPS HARNESS (Asm-Index: 12-14, page 575)

a. Switch OFF the Main Power.b. Disconnect P/J11.c. Check for the continuity between J11 <=> J121 as below:v J11-1 <=> J121-6v J11-2 <=> J121-5 (+5V)v J11-3 <=> J121-4v J11-4 <=> J121-3v J11-5 <=> J121-2v J11-6 <=> J121-1 (+24V)


Go to step 3 Replace the LVPSHarness


Table 35. LVPS (continued)


3.AC WALL OUTLET

Check the AC wall outlet.

Is the AC wall outlet correctly wired and grounded?


Notify customer ortheir electrician.

4.






Paper Size Switch - 500-Sheet Paper Trays

The ″Autosensed Paper″ size indicated on the CONFIG PAGE does not match the tray size guide positions.

The following table shows the combination of size switches activated (’1’) for each size paper.Table 36. Paper Size Switches

Paper SizePaper Size Switch

SW4 Bottom SW3 SW2 SW1 Top

Cassette removed 0 0 0 0

Universal (Non-regular size) 1 0 0 0

11x17 (Ledger) SEF 0 0 0 1

A3 SEF 0 0 1 0

B4 SEF 0 0 1 1

Legal 14″ SEF 0 1 0 0

Legal 13″ SEF 0 1 0 1

A4 SEF ¹ 0 1 1 0

Letter SEF ² 0 1 1 0

B5 LEF 1 1 0 1

Letter LEF 1 0 1 0

A4 LEF 1 0 1 1

Executive LEF 1 1 0 1

A5 LEF ¹ 1 1 1 1

Statement LEF ² 1 1 1 1

Postcard SEF ¹ 0 1 1 1


Table 36. Paper Size Switches (continued)

Paper SizePaper Size Switch

SW4 Bottom SW3 SW2 SW1 Top

C5 SEF ² 0 1 1 1

COM-10 1 1 1 0

DL SEF 1 1 0 0

Monarch SEF 1 0 0 1

Notes:

1. Only when the printer is switched on while pressing ONLINE (Cold Reset to LTR defaults)2. Only when the printer is switched on while pressing CANCEL (Cold Reset to A4 defaults)


Table 37. Paper Size Switch


SUSPECT COMPONENTS

v Paper Cassette (Asm: 2, page 550)


v Cassette Guide Assembly (Asm-Index: 3-6, page 553)


v Tray Lower1 Harness (Asm-Index: 3-2, page 553)



1.

PAPER SIZE CAM (Asm-Index: 2-20, page 550) POSITIONS

Inspect the contact of Size Cam with the Size Actuator (Asm-Index: 3-8, page553). See Table 36 on page 165.

Do the Size Cam states match the loaded paper size?



Table 37. Paper Size Switch (continued)


2.

PAPER SIZE CAM MECHANICS

Inspect the suspect components and their settings relating to the Size Camas:v End Guide Plate (Asm-Index: 2-14, page 550)

v Paper End Guide (Asm-Index: 2-15, page 550)

v End Guide Spring (Asm-Index: 2-16, page 550)

v End Guide (Asm-Index: 2-17, page 550)

v Pivot Plate (Asm-Index: 2-18, page 550)

v Sector Gear (Asm-Index: 2-19, page 550)

v Size Cam (Asm-Index: 2-20, page 550)

Are any of these components damaged or installed incorrectly?

Repair or replacethe PaperCassette asnecessary

If the tray is anoptional Tray 2 or3, install a newTray Feeder(Asm: 20, page697), or replacethe entire option.

For Tray 1,replace theCassette GuideAssembly Left(See page 426).

3.

PAPER SIZE SWITCHES

The cams seem to actuate correctly, but the wrong size is reported.a. Remove the Paper from the Paper Cassette.b. Use “D21 SENSOR TEST” on page 261 to check the Paper Size Switches.

c. Reach inside the paper feeder and press and release one Size Actuator(Asm-Index: 3-8, page 553). Press ENTER and repeat for each switch.

Do the Size Switches function correctly?

Possible MCUproblem

If the tray is anoptional Tray 2 or3, replace theoption.

For Tray 1, go tostep 4.


Table 37. Paper Size Switch (continued)


4.

PAPER SIZE SWITCH OF THE FEEDER PWBa. Remove the Feeder PWB (See page 420).

b. Check for the continuity between two terminals of each Paper Size Switchwhile you press and release it.

Is there continuity through the switch when you press the Size Actuatorand no continuity when you release it?

Go to step 5 Replace theFeeder PWB (Seepage 420)

5. There is a problem with one of the Suspect Components.

6.






Pick Up Solenoid (Auxiliary Tray)

Note: You can test the Auxiliary Tray Pick Up Solenoid using “D50 SOL TRAY A (Auxiliary Tray FeedSolenoid)” on page 277.

Table 38. Pick Up Solenoid


SUSPECT COMPONENTS

v Pick Up Solenoid (Asm-Index: 6-17, page 559)



1.

DANGER


PICK UP SOLENOID POWER SUPPLYa. Remove the Controller Assembly (See page 535).

b. Check the voltage between P/J13-9 <=> ground.

Is there 24VDC between P/J13-9 <=> ground?


2.

CONTINUITY ON MCU PWBa. Power off the printer.b. Disconnect P/J21 from the MCU PWB (Asm-Index: 12-8, page 575).

c. Check for the continuity between P13-9 <=> P21-1.





Table 38. Pick Up Solenoid (continued)


3.

PICK UP SOLENOID (Asm-Index: 6-17, page 559)

a. Power off the printer.b. Disconnect P/J13 from the MCU PWB.c. Check the resistance between J13-9 <=> J13-10.

Is there approximately 90 ohms between J13-9 <=> J13-10?


Go to step 4

4.


a. Leave P/J13 disconnected and disconnect P/J135 from the harnessleading to the MSI Feed Solenoid.

b. Check for the continuity on the two wires.

Is there continuity on both wires?

Replace the PickUp Solenoid (Seepage 477)


5.






Registration SensorTable 39. Registration Sensor


SUSPECT COMPONENTS

v Registration Sensor (Asm-Index: 7-6, page 562)

v Registration Actuator (Asm-Index: 7-7, page 562)





1.

RESISTRATION SENSOR and ACTUATOR (Asm-Index: 7-6 and 7-7, page562)

a. Remove the Rear Tie Plate (part of “Registration Sensor/Actuator” onpage 484).

b. Push up and then release the Registration Actuator and inspect therelative position with the detecting point of the Registration Sensor.

Is the arm of the Registration Actuator away from the detecting point ofthe Registration Sensor when you push up the Actuator? Does the armshield the detecting point of the Sensor when you release the Actuator?

Go to step 2 Replace theRegistrationSensor and/orActuator (Seepage 484)


Table 39. Registration Sensor (continued)


2.

DANGER


REGISTRATION SENSOR POWER SUPPLYa. Remove the Controller Assembly (See page 535).


c. Disconnect P/J13, and then check the voltage between P13-3<=> P13-4.



3.


b. Check for the continuity between P11-5 <=> P13-3.


Go to “LVPS” onpage 163





4.

DANGER


POWER SUPPLY TO THE REGISTRATION PAPER DETECTORa. Leave P/J12, P/J15 and P/J17 on the MCU PWB

disconnected.b. Check the voltage between P/J13-5 <=> P/J13-4.



5.

DANGER


REGISTRATION SENSOR SIGNALa. Leave P/J12, P/J15 and P/J17 on the MCU PWB

disconnected.b. Press and release the Registration Actuator (Asm-Index: 7-7,

page 562).

c. Check the voltage between P/J13-5 <=> P/J13-4.

Is there 0VDC between P/J13-5 <=> P/J13-4 when you pressthe Actuator, and 5VDC when you release it?


Go to step 6




6.


a. Disconnect P/J13 and P/J132.b. Check for the continuity on each wire between J13-3 <=> J132-3, J13-4

<=> J132-2, and J13-5 <=> J132-1.


Replace theRegistrationSensor (See page484)


7.






Toner SensorTable 40. Toner Sensor


SUSPECT COMPONENTS



v Toner Sensor Harness (Asm-Index: 5-17, page 557)



1.

DANGER


TONER SENSOR POWER SUPPLYa. Remove the Controller Assembly (See page 535).


c. Check the voltage between P/J22-1 <=> P/J22-3.



2.


b. Check for the continuity between P22-1<=> P21-1.





Table 40. Toner Sensor (continued)


3.

DANGER


TONER DETECTOR SIGNALa. Leave P/J12, P/J15 and P/J17 on the MCU PWB

disconnected.b. Check the voltage between P22-4 <=> P22-3.



4.

DANGER


TONER DETECTOR SIGNALa. Leave P/J12, P/J15 and P/J17 disconnected.b. Press down and hold the Interlock Switch (Asm-Index: 12-1,

page 575).

c. Check the voltage between P22-4 <=> P22-3 while youremove and reinstall the EP Cartridge.

Is there 0VDC between P22-4 <=> P22-3 when you install theEP Cartridge, and 5VDC when you remove it?


Go to step 5


Table 40. Toner Sensor (continued)


5.

TONER RELAY HARNESS (Asm-Index: 12-18, page 575)

a. Disconnect P/J22 from the MCU PWB and P/J222 from the harnessleading to the Toner Sensor (Asm-Index: 5-14, page 557).

b. Check for the continuity of each wire between J22 <=> J222.


Go to step 6 Replace the TonerRelay Harness

6.

TONER SENSOR HARNESS (Asm-Index: 5-17, page 557)

a. Disconnect P/J221 from the Toner Sensor and leave P/J222 disconnected.b. Check for the continuity of each wire between J221 <=> P222.

Is there continuity between J221 <=> P222?

Replace the TonerSensor Assembly(See page 462)

Replace the TonerSensor Harness

7.






Twinax / Coax NIC Printing ProblemsNotes:1. For Twinax NICs, ensure that the printer station address is set correctly in the TWINAX SETUP MENU

(IPDS ADDR or SCS ADDR).2. If the printer has had a ″cold reset″, have the user ensure that all menus have been tailored to their

original settings. If necessary, see an old Config Page printout.Table 41. Twinax/Coax NIC Printing Problems


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

2.

Print a Config Page (see page 250).

Is IPDS indicated on the Config Page?

Verify that there isenough memoryfor IPDS jobs.Refer to the IBMInfoPrint 20:User’s Guide formemoryrequirements. Goto step 3.

Reseat the IPDSSIMM. If thatdoes not fix theproblem, install anew IPDS SIMM.

3.

Switch on the printer power. Wait for the READY message.

Does READY appear within 5 minutes?

Go to step 4 Return to“Chapter 1.Getting Started”on page 25 with



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


4.

Can you print a printer Config Page? Go to step 5 Return to“Chapter 1.Getting Started”on page 25 with


5. Is the Twinax or Coax NIC indicated on the printer Config Page? Go to step 6 Go to step 10

6. Can you print a NIC Config Page from the Test button on the back of theNIC?


7.

When a job is sent, does the printer operator panel indicate its arrivalwith a message such as ″TX IPDS″ or ″CX IPDS″?

The cabling andNIC are OK.Suspect aproblem withmenu settings,the IPDS SIMM,or the controllerSIMM/board.

Go to step 8




8.

Check the green LED (labelled CU) on the back of the NIC.

Is the green LED On or Blinking?

The NIC isreceiving pollsfrom the system.Suspect a job orconfigurationproblem. Referthe SystemAdministrator tothe IBM NetworkPrinters: Twinaxand CoaxConfigurationGuide or TechSupport.Note: If theShare light is alsoon when theprinter is READY,install a new NIC.

Go to step 9




9.

The NIC can communicate with the controller, but the system cannotcommunicate with the NIC.

Check the cable connection at the back of the Twinax of Coax NIC.

Is the connection OK?

There is probablya network cablingproblem or aconfigurationproblem. Referthe SystemAdministrator tothe IBM NetworkPrinters: Twinaxand CoaxConfigurationGuide or TechSupport (see“Appendix D.TechnicalSupport” onpage 602).

Replace the NIC

10.

There is a problem with the NIC or Controllerv Power off.v Reseat the NICv Power on and wait.



If there is onlyone NIC in theprinter, go to step11. If you haveanother NIC, youcan try swappingNIC positions onthe controller toisolate NIC vsController.




11.

Install a new NIC (See “Network Interface Card” on page 541)



Replace theController SIMM(See “ControllerPWB SIMM” onpage 539)or theController PWB(See “ControllerPWB” onpage 537)

12.






Print QualityBackground

PROBLEM: There is toner contamination on all or part of the page. The contamination appears as a light graydusting.

hc2m211F


Table 42. Background


SUSPECT COMPONENTS









Before starting, inspect the printer paper path. Is it clear of foreignmatter such as staples, paper clips and paper scraps?

1.

PRINT DENSITYa. Find the white volume knob near the left end of the EP cartridge. Ensure

that it is at the nominal position (centered between +1 and -1).b. Adjust CONFIG MENU/DENSITY to a lower setting.c. Run a Test Print.d. If necessary, try adjusting the knob clockwise to a higher position.

Is the background gone?


Go to step 2

2.

EP CARTRIDGEa. Install a new EP Cartridge.b. Run a Test Print.

Is the background gone?


Go to step 3


Table 42. Background (continued)


3.

IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through the

print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the

drum just before the transfer area (BTR).

Are the undeveloped areas of the drum clean and without background?

Go to step 4 Go to “HVPS” onpage 159

4.

TRANSPORT CHUTE ASSEMBLY (Asm-Index: 6-2, page 559) GROUND

a. Remove the EP Cartridge (Asm-Index: 11-40, page 572).

b. Check for the continuity, from the front opening, between metal parts of theTransport Chute Assembly and the Printer Frame.

Is the Transport Chute Assembly grounded?

Go to step 5 Remove andreinstall theTransport ChuteAssembly (Seepage 468), so thatit is groundedproperly.

5.

FUSER ASSEMBLY (Asm-Index: 8-1, page 564) GROUND

a. Open the Fuser Cover Assembly.b. Check for the continuity between the screw located at the back side of the

Fuser Assembly and the Printer Frame.

Is the Fuser Assembly grounded?


Remove andreinstall the FuserAssembly (Seepage 487), so thatit is groundedproperly.


Table 42. Background (continued)


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). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with a black stripe may print. For diagnostics of thisproblem, see “Operator Panel, Controller, and Power Problems” on page 135.

hc2m203F


Table 43. Black Prints


SUSPECT COMPONENTS








1.


Is the print normal?


Go to step 2

2.

HVPS (Asm-Index: 12-11, page 575)

a. Shield the entire window of the ROS Assembly (Asm-Index: 11-20, page572).

b. Run a Test Print.

Is the print black?

Go to “HVPS” onpage 159

Go to step 3

3.

ROS ASSEMBLY (Asm-Index: 11-20, page 572)

a. Shield half of the window of the ROS Assembly.b. Run a Test Print.

Is the print half white and half black?




Table 43. Black Prints (continued)


4.






Blank Prints

PROBLEM: The entire print is blank.


hc2m202F


Table 44. Blank Prints


SUSPECT COMPONENTS











v Pop Up Frame (Asm-Index: 11-1, page 572)

v CRU Latch (Asm-Index: 11-13, page 572)

v CRU Latch Spring (Asm-Index: 11-14, page 572)


1.

EP CARTRIDGEa. Install new EP Cartridge.b. Reprint the problem image.

Is there a normal image on the paper?


Go to step 2


Table 44. Blank Prints (continued)


2.

DRUM GROUNDa. Remove the EP Cartridge.b. Inspect the metal grounding plate on the rear end of the CRU Guide

Assembly R (Asm-Index: 11-30, page 572).

Is the metal grounding plate intact, not contaminated and not deformed?

Go to step 3 Reform or cleanthe MetalGrounding Plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).

3.

GROUND OF THE METAL GROUNDING PLATE

Check for the continuity between the Metal Grounding Plate and the printerframe.

Is there continuity between the Grounding Plate and the printer frame?


4.BTR ASSEMBLY (Asm-Index: 6-1, page 559)

Is the BTR intact, not contaminated?

Go to step 5 Replace BTRAssembly (Seepage 466)

5.

IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF power halfway through the print

cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the


Is the image on the drum completely developed, with sharp, black, easilyread areas?



Table 44. Blank Prints (continued)


6.

IMAGE TRANSFER PROCESS

Inspect the toner image on the drum immediately after the transfer area(BTR).

Was any of the toner image on the drum transferred to the paper?

Problem with theBTR Assembly orwiring


7.






Black Horizontal Stripes

PROBLEM: The print contains black horizontal stripes of varying widths.

Note: The Controller must have at least 1 DRAM memory SIMM installed (in the group of 3 sockets). Sincethere is no DRAM built into the controller, the Controller cannot operate without a DRAM SIMM. Thesymptom with no DRAM is light, solid rectangles on the top line of the operator panel. After severalminutes, unrequested blank pages, or pages with black horizontal stripes of varying widths may print.

To diagnose this problem, see “Operator Panel, Controller, and Power Problems” on page 135.

hc2m215F


Damaged Print

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

hc2m213F


Table 45. Damaged Print


SUSPECT COMPONENTS






v Pick Up Roll (Asm-Index: 6-8, page 559)

v Retard Pad Assembly (Asm-Index: 6-18, page 559)



v Turn Chute Assembly (Asm-Index: 3-5, page 553)

v Turn In Chute (Asm-Index: 3-4, page 553)

v Feed Roll (Asm-Index: 4-1, page 555)



1.PAPER FEED

Observe paper feed.

Is the paper fed crooked?

Go to “SkewedImage” onpage 212

Go to step 2


Table 45. Damaged Print (continued)


2.

PAPER CONDITIONSa. Replace paper with fresh, dry standard paper.b. Run a Test Print.

Is the paper still damaged?


3.


CHECKING THE HEAT ROLL (Asm-Index: 9-10, page 567)and PRESSURE ROLL (Asm-Index: 9-15, page 567)

a. Open the Pop Up Unit.b. Open the Fuser Cover Assembly and the Fuser Rear

Assembly (Asm-Index: 8-10, page 564).

c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll and the Pressure Roll.

Are the Heat Roll and the Pressure Roll free of scratchesand contamination?

Go to step 4 Clean or replacethe FuserAssembly (Seepage 487)

4.

PAPER PATH

Inspect the paper path between the feed tray and the exit tray forcontamination or obstructions.

Is the paper path free of obstructions?

Go to step 5 Removeobstructions orcontaminationfrom the paperpath.


Table 45. Damaged Print (continued)


5.

PAPER PATH ROLLS

Inspect all of the rolls along the paper path between the feed tray and the exittray for contamination, wear or damage.

Are the paper path rolls free of contamination, wear, or damage?

Go to step 6 Replace thedamaged or wornroll. (See“Chapter 6.RemovalProcedures,Adjustments” onpage 394)

6.


Is the print still damaged?


7.






Fusing, Not Fused or Partially Fused Image

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

hc2m214F

Table 46. Fusing, Not Fused or Partially Fused Image


SUSPECT COMPONENTS





1.

PAPER CONDITIONSa. Replace the paper with fresh, dry standard paper.b. Reprint the problem image.




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


2.



a. Open the Pop Up Unit.b. Remove the Fuser Assembly (See page 487).

c. Inspect the Heat Roll and Pressure Roll rotating the Exit Gear(Asm-Index: 9-29, page 567) manually.


Reinstall theFuser Assembly(See page 487).Go to step 3.

Clean or replacethe FuserAssembly (Seepage 487)

3.


a. Rotate the Exit Gear Manually.b. Inspect the contact between the Heat Roll and the Pressure Roll along the

rotation.

Are the Heat Roll and the Pressure Roll contacting each other uniformly?



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


4.






Light (Undertoned) Prints

PROBLEM: The overall image density is too light.

hc2m201F


Table 47. Light (Undertoned) Prints


SUSPECT COMPONENTS












v CRU Latch (Asm-Index: 11-13, page 572)

v CRU Latch Spring (Asm-Index: 11-14, page 572)


1.

PRINT DENSITYa. Find the white volume knob near the left end of the EP cartridge. Ensure

that it is at the nominal position (centered between +1 and -1).b. Adjust the CONFIG MENU/DENSITY setting as needed.c. Reprint the problem image.

Is the image density normal?


Go to step 2


Table 47. Light (Undertoned) Prints (continued)


2.

PAPER CONDITIONSa. Load fresh, dry paper.b. Run a Test Print.



Go to step 3

3.

EP CARTRIDGEa. Install a new EP Cartridge.b. Reprint the problem image.



Go to step 4

4.

DRUM GROUNDa. Remove the EP Cartridge (Asm-Index: 11-40, page 572).

b. Inspect the two Metal Grounding Springs on the rear end of the CRUGuide Assembly L (Asm-Index: 11-30, page 572). They should both havethe same shape.

Are the metal grounding springs intact, not contaminated, and notdeformed?

Go to step 5 Reform or cleanthe metalgrounding plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).

5.

CONTINUITY OF THE METAL GROUNDING PLATE


Is there continuity between the Plate Grounding Plate and the printerframe?





6.

LASER BEAM PATH

Inspect laser beam path between the ROS Assembly (Asm-Index: 11-20, page572) and the Drum.

Is the laser beam path free of obstructions?

Go to step 7 Clean the mirrorand remove anyobstructions fromthe laser beampath.


Is the BTR intact and not contaminated?

Go to step 8 Replace the BTRAssembly (Seepage 466)

8.

IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF the printer power halfway through

the print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the


Is the image on the drum completely developed with sharp, black, easilyread areas?


9.



Is the toner image on the drum transferred completely to the paper?





10.






Residual Image

PROBLEM: There are ghost images on the page. The images may be either ghosts of the previous page orparts of the page being printed.

hc2m210F


Table 48. Residual Image


SUSPECT COMPONENTS










v Heat Roll (Asm-Index: 9-10, page 567)

v Pressure Roll (Asm-Index: 9-15, page 567)


1.REPETITIVE PRINTING

Inspect the residual images.

Was the customer printing numerous copies of the same image?


2.

PAPER CONDITIONa. Replace paper with fresh, dry standard paper.b. Reprint the problem image.

Do residual images still appear?



Table 48. Residual Image (continued)


3.EP CARTRIDGE


Do residual images still appear?


4.BTR ASSEMBLY

Inspect the BTR Assembly for contamination and wear.

Is the BTR free of contamination and wear?


5.


FUSER ASSEMBLYa. Open the Pop Up Unit.b. Remove the Fuser Assembly (See page 487).

c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll (Asm-Index: 9-10, page 567) andPressure Roll (Asm-Index: 9-15, page 567).


Reinstall theFuser Assembly.Go to the step 6.

Clean or replacethe FuserAssembly (Seepage 487)


Table 48. Residual Image (continued)


6.






Skewed Image

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

hc2m212F


Table 49. Skewed Image


SUSPECT COMPONENTS





v Pick Up Roll (Asm-Index: 6-9, page 559)

v Retard Pad Assembly (Asm-Index: 6-18, page 559)

v Front Bottom Tray (Asm-Index: 5-5, page 557)



v Turn Chute Assembly (Asm-Index: 3-5, page 553)

v Turn In Chute (Asm-Index: 3-4, page 553)

v Feed Roll (Asm-Index: 4-1, page 555)





Table 49. Skewed Image (continued)


1.

PAPER FEEDa. Remove the Paper Cassette (Asm: 2, page 550).

b. Verify that the paper guides are adjusted to match the paper size.c. Reload the paper correctly in the Paper Cassette.d. Reinstall the Paper Cassette correctly.e. Open the Turn Chute Assembly (Asm-Index: 3-5, page 553) and ensure

that the Bottom Plate Assembly (Asm-Index: 2-10, page 550) is positionedcorrectly.

f. Reprint the problem image.



2.

PAPER PATH

Inspect the paper path between the feed tray and the exit tray forcontamination or obstructions.



3.

PAPER PATH ROLLSa. Inspect all of the rolls along the paper path, between the feed tray and the

exit tray, for contamination, wear, or damage.b. Ensure that the pinch rolls turn freely and that the spring pressure is even.

Are the paper path rolls free of contamination, wear, or damage?

Go to step 4 Replace thedamaged or wornroll. (See“Chapter 6.RemovalProcedures,Adjustments” onpage 394)


Table 49. Skewed Image (continued)


4.


Is the image still skewed?


5.






Spots

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

hc2m209F

Table 50. Spots


SUSPECT COMPONENTS









Table 50. Spots (continued)


1.


Are the spots gone?


Go to step 2

2.BTR ASSEMBLY




3.


IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway

through the print cycle.b. Carefully remove the EP Cartridge and inspect the toner

image on the drum just before the transfer area (BTR).

Is the image on the drum completely developed, with sharp,black easily read areas and no spots?




Table 50. Spots (continued)


4.






Streaks, Horizontal

PROBLEM: There are black lines running horizontally across the page.


hc2m207F


Table 51. Streaks, Horizontal


SUSPECT COMPONENTS











1.


Are the horizontal streaks gone?


Go to step 2

2.

DRIVE TRANSMISSION

Perform “53 ERROR CALL FOR SERVICE” on page 114 and fix the problemsif any.

Is the rotation of the Main Motor (Asm-Index: 10-6, page 570) transmittedto all the rolls?

Go to step 3 Follow theinstructions in “53ERROR CALLFOR SERVICE”on page 114.


Table 51. Streaks, Horizontal (continued)


3.

DRUM GROUNDa. Remove the EP Cartridge.b. Inspect the metal grounding plate on the rear end of the CRU Guide

Assembly R (Asm-Index: 11-31, page 572).

Is the metal grounding plate intact, not contaminated and not deformed?

Go to step 4 Reform or cleanthe metalgrounding plate,so it makes bettercontact with thedrum shaft, orreplace the CRUGuide AssemblyR (See page510).

4.

CONTINUITY OF THE METAL GROUNDING PLATE


Is there continuity between the Grounding Plate and the Printer Frame?






6.

IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through print


Drum just before the transfer area (BTR).

Is the image on the Drum completely developed; with sharp, black, easilyread areas and no horizontal streaks?



Table 51. Streaks, Horizontal (continued)


7.



Inspect the toner image on the Drum immediately after thetransfer area (BTR).

Was the toner image on the Drum transferred completely tothe paper along with horizontal streaks?


Replace the BTRAssembly (Seepage 466)

8.






Streaks, Vertical

PROBLEM: There are black lines running vertically along the page.


hc2m206F


Table 52. Streaks, Vertical


SUSPECT COMPONENTS









1.


Are the vertical streaks gone?


Go to step 2

2.LASER BEAM PATH

Inspect the laser beam path between the ROS Assembly and the Drum.


Go to step 3 Remove anyobstructions fromthe laser beampath.

3.BTR ASSEMBLY





Table 52. Streaks, Vertical (continued)


4.

PAPER PATH

Inspect the paper path, between feed and exit, for contamination orobstructions.


Go to step 5 Removeobstructions orcontaminationfrom the paperpath

5.



a. Open the Pop Up Unit.b. Open the Fuser Cover Assembly and the Fuser Rear

Assembly (Asm-Index: 8-10, page 564).

c. Rotate the Exit Gear (Asm-Index: 9-29, page 567) manuallyand inspect the Heat Roll and the Pressure Roll.




Table 52. Streaks, Vertical (continued)


6.






Unusual Patterns

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

hc2m216F

Table 53. Unusual Patterns


SUSPECT COMPONENTS


v BTR Assembly (Asm-Index: 6-1, page 559), unseated or bad

v Dirty or bent contacts on the EP Cartridge or BTR Assemblyv HVPS (Asm-Index: 12-11, page 575)



Table 53. Unusual Patterns (continued)


v Exchange the suspected FRUs, one at a time.v Check the following, suspecting an intermittent problem:





Voids

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

hc2m208F

Table 54. Voids


SUSPECT COMPONENTS








Table 54. Voids (continued)


1.

PAPER CONDITIONSa. Load fresh, dry standard paperb. Reprint the problem image.



2.


Note: If the new EP cartridge fixes the problem, the problem may have beencaused by toner clumping in the old EP cartridge. This sometimes happens inhot and humid environments. Shaking the old EP cartridge to break up thetoner clumps may fix the problem. Use caution when shaking the EP cartridgeso that toner is not expelled.



3.

IMAGE DEVELOPMENT PROCESSa. Generate a Test Print and switch OFF printer power halfway through the

print cycle.b. Carefully remove the EP Cartridge and inspect the toner image on the


Is the image on the drum completely developed; with sharp, black easilyread areas and no spot deletions?


4.



Is the toner image on the drum transferred completely to the paper?




Table 54. Voids (continued)


5.






Voids, Horizontal

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

hc2m205F


Table 55. Voids, Horizontal


SUSPECT COMPONENTS












v Registration Clutch Assembly (Asm-Index: 10-9, page 570)




1.

PAPER CONDITIONSa. Load fresh, dry standard paper.b. Reprint the problem image.

Does the problem appear?



Table 55. Voids, Horizontal (continued)


2.

MAIN MOTOR (Asm-Index: 10-6, page 570) and DRIVE TRANSMISSION

a. Refer to “53 ERROR CALL FOR SERVICE” on page 114 for causes ofpossible motor problems.

b. Reprint the problem image.

Does the problem appear?


3.EP CARTRIDGE


Are the horizontal band deletions gone?


Go to step 4





5.

IMAGE DEVELOPMENT PROCESSa. Generate a print and switch OFF printer power halfway through the print



Is the image on the drum completely developed, with sharp, black, easilyread areas and no horizontal band deletions?



Table 55. Voids, Horizontal (continued)


6.



Inspect the toner image on the drum immediately after thetransfer area (BTR).

Was the toner image on the drum transferred completely tothe paper?

Replace theFuser Assembly(See page 487).

Go to step 7.


7.






Voids, Vertical

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

hc2m204F

Table 56. Voids, Vertical


SUSPECT COMPONENTS









Table 56. Voids, Vertical (continued)


1.

PAPER CONDITIONSa. Load fresh, dry standard paper.b. Reprint the problem image.



2.


a. Install a new EP Cartridge.b. Reprint the problem image.



3.LASER BEAM PATH

Inspect the laser beam path between the ROS Assembly and the Drum.


Go to step 4 Remove anyobstructions fromthe laser beampath.

4.

PAPER PATH

Inspect the paper path, between feed and exit, for contamination orobstructions.









Table 56. Voids, Vertical (continued)


6.






Status MessagesPrinter status messages are listed alphabetically.

COLD RESET A4Meaning : The printer is powering up and resetting all menu values to the factory defaults. The A4 papergroup is the default.

Action : None required; however, restore any unique settings for the printer (such as the default tray).

COLD RESET LTRMeaning : The printer is powering up and resetting all menu values to the factory defaults. The LTRpaper group is the default.

Action : None required; however, restore any unique settings for the printer (such as the default tray).

CONTEXT SAVE ADJUSTEDMeaning : The printer is configured to use the context saving option (PCL SAVE and PS SAVE under theMemconfig Menu); however, due to a configuration change, the printer no longer has enough memory tosupport context saving.

Action : Press Continue . To restore context saving, have the customer add more memory to the printer.

CONTEXT SAVE CHANGEMeaning : The values for the PCL SAVE or PS SAVE items under the Memconfig Menu have beenchanged.

Action : Press the Continue key to accept the new values and continue printing.

DSK FMT RESTARTMeaning : The printer is restarting to include the hard drive in its configuration.

Action : None required.


+ FORMAT DISK/- IGNORE DISKMeaning : You are powering up with an unformatted hard drive, or you selected the FORMAT DISKaction on the Test Menu.

Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocontinue as if there were no hard drive installed.

FLUSHING...Meaning : The printer is canceling a PCL5e or PostScript job.


FORMATTINGMeaning : The printer is formatting the hard disk drive.


F/W xxxxxxxMeaning : Firmware error (xxxxxxx can be any alphanumeric value).

Action : Power the printer off, wait ten seconds, and power the printer back on. If problems persist, callfor technical support.

Note: When firmware errors occur, the printer might also print an error page. If the printer does print anerror page, save it so you can tell technical support.

I/O INITIALIZINGMeaning : The network interface card is initializing.

Action : Normally none. If the message remains on the display for more than 5 minutes and nothingprints, go to “Ethernet / Token-Ring NIC Printing Problems” on page 150 or “Twinax / Coax NIC PrintingProblems” on page 179.

Note: If more than one Network Interface Card is installed, remove them one at a time to determinewhich card is causing the problem.


IBM INFOPRINT 20Meaning : The printer power has just been switched on.

Action : Normally none. If the message remains on the display and nothing prints, wait three minutes toverify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the message persists, go to“Operator Panel, Controller, and Power Problems” on page 135.

- IGNORE DISK/+ FORMAT DISKMeaning : You are powering up with an unformatted hard drive, or you selected the FORMAT DISKaction on the Test Menu.

Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocontinue as if there were no hard drive installed.

IPDS COAXMeaning : The printer is receiving IPDS data through the coax interface.


IPDS ETHERNETMeaning : The printer is receiving IPDS data through the Ethernet interface.


IPDS TOKEN-RINGMeaning : The printer is receiving IPDS data through the token-ring interface.


IPDS TWINAXMeaning : The printer is receiving IPDS data through the twinax interface.


JOB QUEUEDMeaning : An informational page is queued for printing.

Action : If the online indicator is off, press the Online key.


KEY NOT VALIDMeaning : You pressed a key that is not valid.

Action : Press another key. In some instances, you may need to press the Online key to use other keyssuch as the Menu key.

MEMCONFIG CHANGEMeaning : You changed a value on the Memory Configuration (Memconfig) Menu.

Action : Press the Continue key to reboot the printer so the new value can take effect.

MEMCONFIG CHANGE 1200 DPI UNAVAILMeaning : You turned on context saving (PCL SAVE or PS SAVE) on the Memory Configuration(Memconfig) Menu. 1200 dpi emulation is no longer available because there is not enough memory.

Action : Press the Continue key to reboot the printer so the new value can take effect. To enable 1200DPI emulation, Have the customer add more memory or turn context saving off.

MENU LOCKEDMeaning : The system administrator has locked the menu. You can view menu settings but you cannotchange them.


MRT COMPRESSIONMeaning : The printer is compressing the page image it is printing because it does not have enoughmemory to print the page without compression.


NEW VALUES AT NEXT BOUNDARYMeaning : You have taken the printer offline while a job was printing to change a menu value. The newvalue might not take effect until the next “job boundary”. Different data streams, in particular SCS, definejob boundaries in different ways, so it may take a while for the new value to take effect.

Action : None required. If problems occur, make sure you take the printer offline to change menu valuesonly when no jobs are printing (the printer is in READY state).


NONIPDS COAXMeaning : The printer is receiving SCS or DSC/DSE data through the coax interface.


NONIPDS TWINAXMeaning : The printer is receiving SCS data through the twinax interface.


OFFLINEMeaning : The printer is offline.

Action : Press the Online key to make the printer active.

ONLINE HEX PRTMeaning : The printer is performing a hexadecimal dump.


PAGES:nnnnMeaning : This is a response to the PAGE COUNT item on the Machine Info Menu, where nnnn is thenumber of pages the printer has printed.


PCL ETHERNETMeaning : The printer is receiving PCL5e data through the Ethernet interface.


PCL PARALLELMeaning : The printer is receiving PCL5e data through the parallel interface.


PCL TOKEN-RINGMeaning : The printer is receiving PCL5e data through the token-ring interface.



PJL PARALLELMeaning : The printer is receiving or sending PJL information through the parallel interface.


PLEASE WAITMeaning : The printer is processing data and cannot immediately respond to a request.

Action : Wait until the message clears. If the message remains and processing on the host appears tohave stopped, power off the printer, wait ten seconds, and then power on the printer.

POWER SAVER ONMeaning : The printer is in power-saving mode and has temporarily shut off power to certain of itscomponents. Power will be restored as soon as a job is submitted.


PS ETHERNETMeaning : The printer is receiving PostScript data through the Ethernet interface.


PS PARALLELMeaning : The printer is receiving PostScript data through the parallel interface.


PS TOKEN-RINGMeaning : The printer is receiving PostScript data through the token-ring interface.


READYMeaning : The printer is ready to receive data.



+ REALLY FORMA T / - IGNORE DISKMeaning : You have asked to format the hard drive.

Action : Press the Value key to format the hard drive. Press the Shift and Value keys simultaneously tocancel the formatting.

RECONFIGURING MEMORYMeaning : The printer has received a print job that requires it to adjust memory settings for the currentpage.

Action : No action is required. The printer reconfigures its memory settings to print the current page.Afterward, its settings revert to normal.

RESETTING PRINTERMeaning : The printer is resetting to its defaults.


RESTORING DEFAULTSMeaning : The printer is restoring the defaults.


SWITCHING TO IPDSMeaning : The printer is switching to IPDS.


SWITCHING TO PCLMeaning : The printer is switching to PCL5e.


SWITCHING TO PSMeaning : The printer is switching to PostScript.



WAIT FOR IDLE PRINTERMeaning : You attempted to print from the Test Menu while the printer was processing PCL, PostScript,or IPDS data.

Action : When a port timeout occurs for the data stream (PCL5e, PostScript, or IPDS), the READYmessage appears on the operator panel. Wait for the READY message and then try printing again.

WARMING UPMeaning : The printer is warming up. When it is warm, it displays the READY message.

Action : None required. If the message seems to appear too frequently, change the value for thepower-saving mode to a larger value. If the message remains on the display and nothing prints, waitthree minutes to verify another (such as 50 ERROR CALL FOR SERVICE) occurs. If the messagepersists, go to “Operator Panel, Controller, and Power Problems” on page 135.


Chapter 3. Diagnostic ToolsOperator Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249Configuration Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251

Running Paper Path Test Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251Printing a Test Matrix Page from the DIAGNOSTICS MENU . . . . . . . . . . . . . . . . . . . . . . . .251Printing a Test Matrix Page Without the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252

Cold Reset. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253MACHINE INFO MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254

Error Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .254Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .256DIAGNOSTICS MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

D01 TEST PRINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257Output Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257D11 CHECK SUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258D13 FUSER TEMP (Current Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259D21 SENSOR TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261D23 TEST FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267D41 CLUTCH TR (Turn Roll Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269D43 CLUTCH REG (Registration Clutch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .271D44 HCF UP (Tray Lifts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273D45 HCF DOWN (Tray Lowers) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275D50 SOL TRAY A (Auxiliary Tray Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279D52 SOLENOID TRAY2 (Tray 2 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281D53 SOLENOID TRAY3 (Tray 3 Feed Solenoid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283D60 DRIVE MOTOR MAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285


D63 MOTOR D CW (Duplex Motor Runs CW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287D64 MOTOR D CCW (Duplex Motor Runs CCW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289D68 HCF MOTOR (HCF Transport Motor). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291

FACTORY ADJ MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293A01 Reg Top 1 (Leading Edge Registration, Tray 1) . . . . . . . . . . . . . . . . . . . . . . . . . . .296A03 Reg Top 2 (Leading Edge Registration, Tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .297A05 Reg Top 3 (Leading Edge Registration, Tray 3) . . . . . . . . . . . . . . . . . . . . . . . . . . .298A07 Reg Top A (Leading Edge Registration, Aux. Tray) . . . . . . . . . . . . . . . . . . . . . . . . . .299A09 Reg Left 1 (Left Edge Registration, Tray 1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300A11 Reg Left 2 (Left Edge Registration, Tray 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301A13 Reg Left 3 (Left Edge Registration, Tray 3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302A15 Reg Left A (Left Edge Registration, Aux. Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . .303A21 Fuser Temp (Adjustment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304S/N = 00-00000 (Serial Number) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305

Menu Items Not Described . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306

Chapter 3. Diagnostic Tools 248

Operator Control Panel

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


Configuration Page1. Press Online to take the printer offline.2. Press Menu . The message TEST MENU appears.3. Press Item . The message CONFIG PAGE appears in the second line.4. Press Enter to print the configuration page.

Notes:1. The configuration pages print from the PAPER MENU/SOURCE.2. To print continuous configuration pages, press Item until CONTINUOUS TEST appears, then press Enter .

To stop, press Cancel Print and wait for up to 10 pages.3. To print duplex continuous configuration pages, set PAPER MENU/DUPLEX=ON.4. If the serial number printed on the configuration page does not match the printer serial number, see

“S/N = 00-00000 (Serial Number)” on page 305. (See Figure 5 on page 363 for the location of the printerserial number.)


Test Prints

Running Paper Path Test Prints1. Press Online to take the printer offline.2. Press Menu to select PAPER MENU.3. Press Item to scroll to the desired input paper SOURCE.4. Press Enter . An asterisk (*) appears next to your choice.5. Press Menu to scroll to the TEST MENU.6. Press Item to scroll to the desired test page.v CONFIG PAGE prints the menu settings.v DEMO includes shading.v CONTINUOUS TEST prints multiple configuration pages (press Cancel Print to stop printing after 10 or

so pages).7. Press Enter to print the test page.

Printing a Test Matrix Page from the DIAGNOSTICSMENUGo to “D01 TEST PRINT” on page 257.


Printing a Test Matrix Page Without the ControllerThis procedure prints a test page without a controller installed. It provides a ground spike to the test printsignal (/TESTPRINT) at MCU P23, which creates the test page. The procedure can help isolate MCU or printengine problems versus controller problems (if the test page prints, the MCU and the print engine arefunctional). It can be used for adjusting print registration from Tray 1.1. Power OFF the printer.2. Remove the controller.3. Locate P23, which is the 2-pin connector near the upper right corner of the MCU (there is no cable

attached).4. Close the printer covers. Ensure that tray 1 has paper and is installed.5. Connect a jumper to the pins of P23.

Note: If you do not have a jumper, you can use one from a Controller SIMM. Before removing a jumper,note its location for reinstallation.

6. Power ON the printer. The main motor and the fan turn on as the MCU tests the printer.7. If the MCU and the print engine are operating correctly, a test page prints within two minutes.

Note: If a test page does not print, ensure that the jumper in P23 is secure. Retry the procedure. If a testpage still does not print, ensure that there are no error conditions, such as an empty paper tray,paper jam, or open covers.

8. Test pages will continue to print (simplex) until the jumper is removed. If the duplex option is installed,removing and replacing the jumper will print test pages (duplex) until the jumper is removed again.

9. If you used a jumper from a Controller SIMM, reinstall the jumper on the Controller SIMM.

Note: MCU-detected errors, such as a fan problem, cause the printer to stop before printing a test page.With the controller installed, these MCU-detected errors display with error codes of 5n (See“Chapter 2. Diagnosing Problems” on page 37).


Cold ResetThe following procedure resets all values in printer NVRAM to factory defaults, and clears the error log.1. Print a configuration page (see “Configuration Page” on page 250).




MACHINE INFO MENU

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

Note: ″Common″ errors, such as COVER OPEN, are not logged.5. Press Value to scroll through the list.6. Press Shift and Enter at the same time to clear the error log.

Note: The Error Log can also be printed by “Running Paper Path Test Prints” on page 251.


CountersThe Machine Info Menu also displays information about printer supply usage. From the Machine Info Menu,select the desired counter:

Machine Info Menu Item Description

PAGE COUNT Displays the number of pages the printer has printed.

ERROR LOG Displays the error log. Use the Value key to scroll through the list.

TONER COUNTER Displays the EP cartridge count. IBM recommends resetting this counterwhenever you change toner cartridges. To reset the counter:1. Simultaneously press the Shift and Value keys.2. Press the Enter key.

FUSER COUNTER Displays the fuser counter. IBM recommends resetting this counterwhenever you change the usage kit. To reset the counter:1. Simultaneously press the Shift and Value keys.2. Press the Enter key.


Service ModeThe service mode consists of two service menus: the DIAGNOSTICS MENU and the FACTORY ADJ MENU.

To display a service menu:1. Power OFF the printer.2. Turn on the printer power while pressing Item and Value simultaneously for a few seconds. Wait until the

message DIAGNOSTICS MENU appears.3. Press Menu to select the service menu (DIAGNOSTICS MENU or FACTORY ADJ MENU).

To select a test or item in the DIAGNOSTICS MENU or FACTORY ADJ MENU:1. Press Item to scroll through the tests or items.2. Press Enter when you reach the test or item you want to run.3. Press Cancel Print to temporarily stop an action test, such as a ‘motor running’ test. Then press Enter to

restart the same test.


DIAGNOSTICS MENUD01 TEST PRINT

Prints a test matrix page from Tray 1. Before performing this test, make sure Tray 1 has paper.

There is no error reporting with this test.

To run D01 TEST PRINT:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).

2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D01 TEST PRINT displays.4. Press Enter to begin printing from Tray 1.5. After the print completes, press Item to step to another item in the DIAGNOSTICS MENU

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

Output Tests

The output tests fall into two groups:v Displaying the fuser temperature control setting and the current fuser temperaturev Actuating components

Once the unit starts executing an output test, the only diagnostic codes accessible are those for output tests.It is thus impossible to break out of the output test mode.

Turning the interlock switch off is another way of terminating the display of the accumulated print count.

The output tests permit the parallel operation of multiple components.


D11 CHECK SUM

The diagnostic test displays the checksum of the printer ROM. The LCD displays the checksum as a four-digitnumber.

To run D11 CHECK SUM:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).

2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D11 CHECK SUM displays.4. Press Enter to begin test.5. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.


D13 FUSER TEMP (Current Setting)

Diagnostic code D13 executes immediatly if any of the other output tests is being executed.

To run D13 FUSER TEMP:1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).

2. Repeatedly press Item to step through the test or items.3. Stop pressing Item when D13 FUSER TEMP displays.4. Press Enter to begin test. A screen displays the factory adjustment fuser temperature (SET) and the actual

fuser temperature (ACT) in HEX.

Note: If you need to change the SET value, go to “A21 Fuser Temp (Adjustment)” on page 304.

5. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Note: Because the fuser is constantly moving through a range of temperatures (warming and cooling), it isnormal for the fuser temperature to change as you run the test.

Check the two-digit hexadecimal number that appears in the lower right corner of the LCD. It is a code thatgives the two running temperatures for controlling the fuser temperature: the normal temperature and the hightemperature.


The following chart lists the temperature code settings and the corresponding temperature ranges.Table 57. Fuser Temperature Codes

Code Temperature Code Range

[Normal Temp./High Temp.] (Hexadecimal)

Fuser Temperature

[Normal Temp./High Temp.]

(°C) Approximate

0 C2 / B2 155 / 172

1 BF / AF 158 / 175

2 BC / AC 162 / 178

3 B9 / A9 165 / 181

4 B6 / A6 168 / 184

5 B3 / A3 171 / 187

6 B0 / A0 174 / 190

7 AD / 9D 177 / 193

8 AA / 9A 180 / 196

9 A7 / 97 183 / 199

A A4 / 94 186 / 202

B A1 / 91 189 / 205

C 9E / 8E 192 / 208

D 9B / 8B 195 / 211

E 98 / 88 198 / 215

F 95 / 85 201 / 218


D21 SENSOR TEST

This diagnostic test checks the function of sensors and switches within the printer.

Note: The toner sensor input test does not work if the interlock switch is off.

To run D21 SENSOR TEST:

1. Enter the DIAGNOSTICS MENU (See “Service Mode” on page 256).

2. Press Item to step through the tests or items.3. Stop pressing Item when D21 SENSOR TEST displays.4. Press Enter to begin test.5. Manually activate and deactivate the sensor or the switch you want to test. If a sensor or switch is

functioning correctly, ″SENSOR OK″ displays. If the sensor is not functioning correctly, ″Activate Sensor″continues to display.

6. To exit this test activate a sensor that functions correctly, then press Item to step to another item in theDIAGNOSTICS MENU.

Note: See Figure 3 on page 265 and Figure 4 on page 266 for the locations of the following items.


Items Tested and Relevant Procedures:

Item Procedure

Interlock switch With the EP cartridge removed, open and close the pop up unit to turn the interlockswitch off and on.

Fuser cover switch Open and close the fuser cover to turn the fuser cover switch off and on.

CRU switch in CRU sensor assembly(See Caution <2–33>).

First disconnect either the P/J12 connector on the MCU PWB or the P/J112 connectorin the ROS assembly. With the pop up unit open, use a small screwdriver or otherimplement to turn the CRU sensor assembly actuator on and off.

Feeder PWB paper size switches fortrays 1-3

Use your hand or other means to move the size actuators and thus turn the feederPWB paper size switches on and off.

AUX tray no paper sensor Use your hand or other means to move the AUX tray no paper actuator to switch theAUX tray no paper sensor between its no paper and paper positions.

Tray 1, 2, or 3 no paper sensor Use your hand or other means to move the tray 1, 2, or 3 no paper actuator to switchthe tray 1, 2, or 3 no paper sensor between its no paper and paper positions.

Registration sensor Use a sheet of paper or other means to move the registration actuator to switch theregistration sensor between its no paper and paper positions. You may need aflashlight to see the actuator in the small rectangular recess at the center of the areabehind the toner cartridge.

Exit sensor Open the fuser cover and the fuser jam access cover. Use a sheet of paper or othermeans to move the exit actuator to switch the exit sensor between its no paper andpaper positions. The sensor is part of the fuser.

Full stack sensor Use your hand or other means to move the full stack actuator to switch the full stacksensor between its no paper and paper positions. The sensor is ignored if the Duplexoption is installed.


Item Procedure

Toner sensor Disconnect P/J171 at the CRU sensor assembly or P/J17 at the MCU; this ensures thatthe laser will not turn on if you accidentally activate the CRU sensor. If the duplexoption is installed, you can open the duplex cover to disable the laser. With theinterlock switch on, install and remove an EP cartridge containing toner, or activate witha non-magnetic metal tool.

Duplex cover switch 1 With the duplex unit lower cover closed, open and close the duplex unit upper cover toturn the duplex cover switch 1 on and off.

Duplex cover switch 2 With the duplex unit upper cover closed, open and close the duplex unit lower cover toturn the duplex cover switch 2 on and off.

Duplex pass sensor Open the duplex unit upper cover. Use your hand or other means to move the duplexpass sensor actuator and thus turn the duplex pass sensor on and off.

DUP stack sensor Use your hand or other means to move the DUP stack actuator to switch the DUPstack sensor between its no paper and paper positions.

HCF Exit sensor Open the HCF rear cover. Override the left and right cover open switches. Cover anduncover the sensor.

HCF Lower position sensor Cannot be tested with D21.

HCF size sensor Remove the left hand side plate. Depress the switch.

HCF Near empty sensor Remove the front cover. Depress the switch.

HCF left hand cover open switch Open the HCF rear cover on the left side only. Opening the cover will change the stateof the switch.

HCF right hand cover open switch Open the HCF rear cover on the right side only. Opening the cover will change thestate of the switch.

HCF tray set sensor 1 With the HCF drawer pulled out and the elevator in the down position, depress both thetray set sensor 1 and tray set sensor 2. Activate D21 and release tray set sensor 1.(Do not allow the bottom plate to rise near the top of the drawer. Damage will occur bynot coming in contact with the upper limit switch).


Item Procedure

HCF tray set sensor 2 Cannot test with D21

Upper limit switch With the elevator in the down position, open the front door and activate D21. Reachinside and push up on the feed roller bracket until you hear a click. This will activatethe upper limit switch.

HCF paper level sensor Push the actuator up into the paper level sensor.

HCF paper out sensor Push up on the paper out sensor. The paper out actuator and sensor are part of thefeed roller bracket assembly.


Full StackSensor

Exit SensorCRU Switch

RegistrationSensorToner

Sensor

MSI (Aux)No Paper Sensor

Fuser Assembly

Full StackSensor

Full Stack Actuator

Exit RollAssembly

Exit Sensor

Exit Actuator

Exit ChuteRoll

Pinch Roll

RegistrationSensor

RegistrationActuator

Pick UpRoll

Metal RegistrationRoll

Rubber RegistrationRoll

hc2m979F

Control Assembly(Console Assembly)

Figure 3. Sensor and Switch Locations I


CST No Paper Sensor

Interlock Switch

Fuser Cover Switch

Paper SizeSwitch

Feeder PWB

Interlock ActuatorFuser Cover Pop Up Cover Assembly

CST No Paper Sensor

Feed Roll

CST No Paper Actuator

Paper SizeSwitch

Size Actuator

Size Cam

FRONT

hc2m980F

Fuser Cover Switch Interlock Switch

Figure 4. Sensor and Switch Locations II


D23 TEST FAN

This diagnostic test runs the fan at high speed.

MCU

Fan

hc2m993F

FRONT


To run D23 TEST FAN:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D23 TEST FAN displays.4. Press Enter to begin test.5. Verify that when you press Enter , the fan is running at high speed.

Verify that the fan is running at high speed from the noise that it makes or from the wind pressure.6. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.

Note: The fan runs at low speed whenever the power is on. It switches to high speed when the main motor ison. This test switches the fan from low speed to high speed.


D41 CLUTCH TR (Turn Roll Clutch)

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

MCU PWB

ElectromagneticTurn Roll Clutch(Tray 1)

ElectromagneticTurn Roll Clutch(Tray 2)

ElectromagneticTurn Roll Clutch(Tray 3)hc2m985F

FRONT


To run D41 CLUTCH TR:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D41 CLUTCH TR displays.4. Press Enter to begin test.5. Verify that when you press Enter , the turn roll clutch actuates.

Confirm clutch operation by listening for the slight click of operation or manually rotating the correspondingdriven rollers (rubber registration roll and turn roll assembly) to confirm that they are no longer free, butfixed to the drive system.



D43 CLUTCH REG (Registration Clutch)

This diagnostic code tests the Registration Clutch Assembly.

MCU PWB

Registration Clutch Assembly

MetalRegistration Roll

hc2m986F

FRONT


To run D43 CLUTCH REG:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D43 CLUTCH REG displays.4. Press Enter to begin test.5. Verify that when you press Enter , the registration clutch actuates.

Confirm clutch operation by listening for the slight click of operation or manually rotating the correspondingdriven rollers (rubber registration roll and turn roll assembly) to confirm that they are no longer free, butfixed to the drive system.



D44 HCF UP (Tray Lifts)

This tests the lifting of the bottom plate.

hc2m026F

2

1

1


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.


D45 HCF DOWN (Tray Lowers)

This tests the lowering of the bottom plate.

hc2m026F

2

1

1


To run D45 HCF DOWN, perform the following:


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



D50 SOL TRAY A (Auxiliary Tray Feed Solenoid)

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

MCU PWB

Pick Up Solenoid hc2m983F


To run D50 SOL TRAY A:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D50 SOL TRAY A displays.4. Press Enter to begin test.5. Verify that when you press Enter , the AUX feed solenoid actuates.

Confirm solenoid operation by listening for the slight click of operation or watching for the rotation of thecorresponding shaft or roller when the power is turned off and on after the execution of the diagnosticroutine.

6. The solenoid may now be in a pre-pick condition. Remove paper from the Auxiliary Tray and switch theprinter off, and then on to reset the solenoid (if you do not remove paper you may get a 24 PAPER JAMwhen the motor is tested during power up).


D51 SOLENOID TRAY1 (Tray 1 Feed Solenoid)

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

Feed Solenoid

Feed Solenoid

Feed Solenoid

MCU PWB

hc2m984F

FRONT

D51

D52

D53


To run D51 SOLENOID TRAY1:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D51 SOLENOID TRAY1 displays.4. Press Enter to begin test.5. Verify that when you press Enter , the Tray 1 feed solenoid actuates.






Feed Solenoid

Feed Solenoid

Feed Solenoid

MCU PWB

hc2m984F

FRONT

D51

D52

D53


D60 DRIVE MOTOR MAIN

The diagnostic code switches on the Main Motor.

MCU PWB

Main Motor

hc2m987F

FRONT


To run D60 DRIVE MOTOR MAIN:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D60 DRIVE MOTOR MAIN displays.4. Press Enter to begin test.5. Verify that when you press Enter , the main motor switches on and rotates.

Confirm motor operation by listening for the sound of operation or by visual observation.6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the

test.7. After the test completes, press Item to step to another item in the DIAGNOSTICS MENU.


D63 MOTOR D CW (Duplex Motor Runs CW)

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

hc2m823F

Duplex Motor

DuplexUpper Roll

DuplexLower Roll

Pinch Roll

Rear RollAssembly

Duplex Sensor


To run D63 MOTOR D CW:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D63 MOTOR D CW displays.4. Press Enter to begin test.5. Verify that when you press Enter , the duplex motor switches on and rotates.

Confirm motor operation by listening for the sound of operation or by visual observation.6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the



D64 MOTOR D CCW (Duplex Motor Runs CCW)

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

hc2m823F

Duplex Motor

DuplexUpper Roll

DuplexLower Roll

Pinch Roll

Rear RollAssembly

Duplex Sensor


To run D64 MOTOR D CCW:


2. Repeatedly press Item to step through the tests or items.3. Stop pressing Item when D64 MOTOR D CCW displays.4. Press Enter to begin test.5. Verify that when you press Enter , the duplex motor switches on and rotates in a counter-clockwise

direction (Open the cover and override the interlock to watch the motor rotate).6. You can press Cancel Print to temporarily stop the test, and then press Continue /Enter to restart the


Confirm motor operation by listening for the sound of operation or by visual observation.


D68 HCF MOTOR (HCF Transport Motor)

hc2m042F

2

1


To run D68 HCF MOTOR:


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



FACTORY ADJ MENUTable 58. Factory Adjustment Menu Items

Code Message Function

A01 Reg Top 1 Sets the top (lead) edge registration for paper fed from tray 1.

0-15 (16 steps) (Factory default 10)

0=Narrowest top edge registration gap

15=Widest top edge registration gap (approximately 0.5 mm per step)

(Go to “A01 Reg Top 1 (Leading Edge Registration, Tray 1)” on page 296.)












Table 58. Factory Adjustment Menu Items (continued)


A07 Reg Top A Sets the top (lead) edge registration for paper fed from auxiliary tray.




(Go to “A07 Reg Top A (Leading Edge Registration, Aux. Tray)” on page 299.)

A09 Reg Left 1 Sets the left edge registration for paper fed from tray 1.


0=Narrowest left edge registration gap

8=Widest left edge registration gap (approximately 0.5 mm per step)

(Go to “A09 Reg Left 1 (Left Edge Registration, Tray 1)” on page 300.)







Table 58. Factory Adjustment Menu Items (continued)







A15 Reg Left A Sets the left edge registration for paper fed from auxiliary tray.




(Go to “A15 Reg Left A (Left Edge Registration, Aux. Tray)” on page 303.)

A21 Fuser Temp Sets the rated fuser temperature.Note: This setting is intended for manufacturing and engineering use. Keep atfactory default.


0=Lowest rated temperature.

15=Highest rated temperature. (approximately 4.0°C per step)

(Go to “A21 Fuser Temp (Adjustment)” on page 304.)


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

This factory adjustment sets the top (lead) edge registration for paper fed from Tray 1.

Use A01 REG TOP 1 to verify that there is a registration problem in Tray 1. (See page 257.)

To perform the adjustment:

1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).

2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A01 REG TOP 1 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory

adjustment value (See Table 58 on page 293).

5. Stop when the desired value displays. Press Enter to write the value to engine NVRAM. An asteriskfollowing the value indicates the value is stored in engine NVRAM.

6. After the adjustment, press Item to step to another item in the FACTORY ADJ MENU.




Use a real job printed from Tray 2 to verify that there is a registration problem.

To perform the adjustment:1. Enter the FACTORY ADJ MENU (See “Service Mode” on page 256).

2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A03 REG TOP 2 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory









2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A05 REG TOP 3 displays.4. PressValue to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory





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

This factory adjustment sets the top (lead) edge registration for paper fed from the AUX tray.

Use a real job printed from the AUX tray to verify that there is a registration problem.


2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A07 REG TOP A displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory





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

This factory adjustment sets the left edge registration for paper fed from Tray 1.

Use D01 TEST PRINT to verify that there is a registration problem. (See page 257.)



2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A09 REG LEFT 1 displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory





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

This factory adjustment sets the left edge registration for paper fed from the auxiliary tray.

Use a real job printed from the AUX tray to verify that there is a registration problem.


2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A15 REG LEFT A displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory





A21 Fuser Temp (Adjustment)

This factory adjustment sets the fuser temperature.

Use D13 FUSER TEMP (Current Setting) to show the current setting and actual reading. (See page 259.)



2. Repeatedly press Item to step through the adjustments or items.3. Stop pressing Item when A21 FUSER TEMP displays.4. Press Value to increase a factory adjustment value (″CODE″). Press Shift +Value to decrease a factory

adjustment value (See Table 57 on page 260 and Table 58 on page 293).




S/N = 00-00000 (Serial Number)

The following procedure enters the printer serial number into the printer MCU NVRAM (see Figure 5 onpage 363 for the location of the printer serial number). This allows the correct serial number to print on theconfiguration page. This value is set at the factory. Use this procedure only if you have installed a new MCUPWB.

To run S/N = 00-00000, perform the following:

1. Enter the FACTORY ADJ MENU (see “FACTORY ADJ MENU” on page 293).

2. Repeatedly press Shift +Item to wrap to the end of the menu item list, S/N = 00-00000 will be displayed.You are now ready to change the left most position of the serial number.

3. Press Value to increase the number, or press Shift Value to decrease the number in that position.Each position has a numerical range from 0–9, and an alpha range from A–F.

4. Press Enter to accept the value and move to the next position.5. Repeat for each position. After the last position is enterd, press Enter again until an asterisk appears at

the right of the serial number. This indicates that the updated serial number information has been stored inthe printer NVRAM.

6. Switch printer power off, and then on again.


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


Chapter 4. Circuit DiagramsMaster Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310Wiring and Signal Description between Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311

MCU ⇔ LVPS ⇔ INTERLOCK SWITCH and FANs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .311Signal names for the MCU ⇔ LVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312

MCU ⇔ FUSER ASSEMBLY ⇔ LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .313Signal names for the MCU ⇔ Fuser Assembly path . . . . . . . . . . . . . . . . . . . . . . . . . . .314Pin numbers and voltage levels for the MCU ⇔ Fuser Assembly path . . . . . . . . . . . . . . . . . .314

MCU ⇔ ROS and CRU SENSOR ASSEMBLY (CRU SWITCH and LD SWITCH) . . . . . . . . . . . . .315Signal names for the MCU ⇔ ROS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .316Pin numbers and voltage levels for the MCU ⇔ ROS path . . . . . . . . . . . . . . . . . . . . . . . .317Selection of the print resolution with SP11 and SP12 . . . . . . . . . . . . . . . . . . . . . . . . . . .318

MCU ⇔ HVPS ⇔ EP CARTRIDGE (BCR and MAG. ROLL), BTR, and DETACK SAW . . . . . . . . . .319Signal names for the MCU ⇔ HVPS path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320Pin numbers and voltage levels for the MCU ⇔ HVPS path . . . . . . . . . . . . . . . . . . . . . . .321

MCU ⇔ REG. CLUTCH, REG. SENSOR, PICK UP SOLENOID, and AUX TRAY NO-PAPER SENSOR. .322Signal names for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux Tray No-Paper

Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323Pin numbers and voltage levels for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux

Tray No-Paper Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324MCU ⇔ FEEDER1 PWB ⇔ FEED SOLENOID, CST NO-PAPER SENSOR, and ELECTROMAGNETIC

CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325Signal names for the MCU ⇔ FEEDER1 PWB path . . . . . . . . . . . . . . . . . . . . . . . . . . .326Pin numbers and voltage levels for the MCU ⇔ FEEDER1 PWB path . . . . . . . . . . . . . . . . . .328

MCU ⇔ MAIN MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329Signal names for the MCU ⇔ Main Motor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330Pin numbers and voltage levels for the MCU ⇔ Main Motor path. . . . . . . . . . . . . . . . . . . . .330

MCU ⇔ TONER SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331


Signal names for the MCU ⇔ Toner Sensor path . . . . . . . . . . . . . . . . . . . . . . . . . . . . .331Pin numbers and voltage levels for the MCU ⇔ Toner Sensor path. . . . . . . . . . . . . . . . . . . .331

MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH or MCU ⇔ FUSER COVER SWITCH . . . . . .332Signal names for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH path . . . . . . . . . . .333Pin numbers and voltage level for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH path . .333Signal names for the MCU ⇔ FUSER COVER SWITCH path . . . . . . . . . . . . . . . . . . . . . .333Pin numbers and voltage level for the MCU ⇔ FUSER COVER SWITCH path. . . . . . . . . . . . . .333

CONTROLLER ⇔ CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334Signal names for the Controller ⇔ Control Panel path . . . . . . . . . . . . . . . . . . . . . . . . . .335Pin numbers and voltage levels for the CONTROLLER ⇔ CONTROL PANEL path . . . . . . . . . . .336

CONTROLLER ⇔ MCU and LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337Signal names for the Controller ⇔ MCU path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338Pin numbers and voltage levels for the Controller ⇔ MCU path . . . . . . . . . . . . . . . . . . . . .338Signals between the Controller and the MCU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339

MCU ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feed Solenoid, No Paper Sensor, andElectromagnetic Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342Signal names for the Feeder PWB ⇔ Feeder PWB path . . . . . . . . . . . . . . . . . . . . . . . . .344Pin numbers and voltage levels for the Feeder PWB (Feeder1) ⇔ Feeder PWB (Feeder2) path . . . . .345Pin numbers and voltage levels for the Feeder PWB (Feeder2) ⇔ Feeder PWB (Feeder3) path . . . . .346Detection of the Feeder configuration through the FEEDER CHECK signal. . . . . . . . . . . . . . . .347

MCU ⇔ Duplex I/F PWB⇔ Duplex PWB and Fuser Cover Switch Duplex PWB ⇔ Dup Stack Sensor,Dup Cover Switch1, Dup Cover Switch2, Duplex Pass Sensor, Duplex Motor, and Offset Motor . . . . .349Signal names for the Duplex I/F PWB ⇔ Duplex PWB path . . . . . . . . . . . . . . . . . . . . . . .350Pin numbers and voltage levels for the Duplex I/F PWB ⇔ Duplex PWB path . . . . . . . . . . . . . .351Signal names for the Duplex PWB ⇔ Offset Motor path . . . . . . . . . . . . . . . . . . . . . . . . .351Pin numbers and voltage levels for the Duplex PWB ⇔ Offset Motor path . . . . . . . . . . . . . . . .352

HCF LVPS⇔ Components, HCF LVPS ⇔ FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . .353Signal names for the HCF LVPS ⇔ Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354Signal names for the HCF LVPS ⇔ FEEDER PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . .356

Chapter 4. Circuit Diagrams 308

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


Master Wiring Diagram

M M

M

CONTROLPANEL

CONTROLLER

LVPS

DUPLEX INTERFACE PWB

FUSER

COVERSWITCH

COVERSWITCH

DUPLEX PWB

MCU

HVPS

EP Cartridge

ROS

LD SOS MOT

OCTMOT

DUPMOT

MAIN MOT

CRU SNS

TONERSNS

REGCLH

REG SNS

NOP SNSAUX

AUXFEEDSOL

MAIN FAN

ACINLET

INTERLOCKSWITCH

TEST PRINT

FULLSNS

/DUPCOVER

SWITCH1

/DUPCOVER

SWITCH2DUPSNS

P/J197

P/J195

DB CR DTS TR

P/J186

P/J196

P/J192

P/J193

P/J198

P/J184 P/J187

P183

P/J151

P/J15

P/J112

P/J113

P/J114

P/J12

P/J16

P/J17

P/J22

P/J13

P/J18

P/J180

P/J142

P/J942

J131 CN1

P/J14

P/J31

P/J19

P/J20

P207

P207

P/J122 P/J

123

P/J126

P/J127 P/J121

P/J11P/J21

P23

P/J124

P/J132

P/J134

P/J171

P/J145

P/J144

P/J

922

P/J

222

P/J

131

P/J

131

P/J

937

P/J

135

P/J

143

P/J

137

P/J

935

P/J

943

P182

EXITSENSOR

FULL STACKSENSOR

HEATER ROD

TEMPERATURESENSOR

THERMOSTAT THERMALFUSE

MAIN SWITCH

J130

FEEDER1P/J203

P202

TURNCLH

NOPAPER

FEEDSOL

P/J

204

P/J

904

P/J

205

P/J

206

P201

FEEDER2P/J203

P202

TURNCLH

NOPAPER

FEEDSOL

P/J

204

P/J

904

P/J

205

P/J

206

P201

FEEDER3P/J203

TURNCLH

NOPAPER

FEEDSOL

P/J

204

P/J

904

P/J

205

P/J

206

P201

P/J

221

P/J190

HC2M994F

OPTIONAL

OPTIONAL


Wiring and Signal Description between Components

MCU ⇔ LVPS ⇔ INTERLOCK SWITCH and FANs

MCU

LVPS

INTERLOCKSW

INTERLOCKSW

MAIN FANFG

FG

AC

L N

24VDC

24VDC

P/J123

P/J11

P/J21

P/J121

P/J122 P124

2

1

1

2

3

4

5

6

6

5

4

3

2

1

RTN

5VDC

SG

/HEAT(TTL)

FAN ALARM(TTL)

/FAN FAST ON(L)24VDC

FAN

ON

FAN

ALA

RM

(TT

L)

RT

N

FANCONTROL

HEATERCONTROL

24VDCSUPPLY

5VDCSUPPLY

hc2m995F

1 2 3

1

1 2 3


Signal names for the MCU ⇔ LVPS pathSignal Name Description

/HEAT (TTL) Fuser control signal to switch AC power to the Heater Rod on and off.

Low: On, High: Off

FAN ALARM (TTL) Fan monitor signal. Goes High when the rotation of the Main Fan is abnormal.

/FAN FAST ON(L) 24V Fan speed switching signal that switches the speed of rotation of the Main Fan between Highand Low.

Low: High speed, High: Low speed


MCU ⇔ FUSER ASSEMBLY ⇔ LVPS

FUSER

FG FG

MCU

LVPS

FGAC

L

N

HEATER

CONTROL

FULL STACK SENSOR

EXIT SENSOR

HEAT ROLL

P/J145 P/J942 P/J142 P/J14

P/J124P146-1

FUSER COVEROPEN SWITCH

J146-1

5VDC

P/J143 P/J943

P/J144

1

2

3

1

2

3

1

2

2

1

TEMPERATURESENSOR

HEATER ROD

THERMOSTAT THERMAL FUSE

PRESSURE ROLL

ELIMINATOR

AC L AC L

AC N AC N

/FULL(TTL)

SG

P.UP

TEMP.

SG

/EXIT(TTL)

SG

P.UP

A1

A2

A3

A4

B1

B2

B3

B4

4

3

2

1

8

7

6

5

4

3

2

1

1

2

3

A4

A3

A2

A1

B1

B2

B3

B4

hc2m996F


Signal names for the MCU ⇔ Fuser Assembly pathSignal Name Description

/EXIT (TTL) Signal from the Exit Sensor. This signal is Low when the Exit Sensor is activated.

TEMP. Temperature monitor signal (analog signal) from the Temperature Sensor Assembly (Thermistor) thatindicates the temperature of the Heat Roll surface.

/FULL (TTL) Signal from the Full Stack Sensor. This signal is Low when the Full Stack Sensor is activated by thestack of printed sheets higher than the predetermined height.

Pin numbers and voltage levels for the MCU ⇔ Fuser Assembly path

P14 P142 P942 Signal Name Signal Direction TriggerHighLevel

LowLevel Note

3 B2 B2 P144-1 /EXIT (TTL) MCU⇐Fuser Level TTL TTL

5 A4 A1 P943-1 P143-2 TEMP. MCU⇐Fuser * * * Analog

8 A1 A4 P145-1 /FULL (TTL) MCU⇐Fuser Level TTL TTL


MCU ⇔ ROS and CRU SENSOR ASSEMBLY (CRUSWITCH and LD SWITCH)

MCU

ROS

MOT

1

2

3

4

5

6

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

1 2 3 4

4 3 2 1

24VDC

RTN

/RMOT ON(TTL)

/SP11(TTL)

/SP12(TTL)

5VDC

/SOS(TTL)

SG

5VDC-LD

SG

VL1

VL2

MO

5VDC

/P.DATA(TTL)

5VD

C

5VD

C-L

D

SG

NO

CR

U

1

2

3

1

2

3

4

5

6

7

CRU SENSOR

SOS

LD

P/J114

P/J113

P/J112

P/J125VDC

LDSWITCH

CRUSWITCH

P/J17

P/J171

hc2m997F


Signal names for the MCU ⇔ ROS pathSignal Name Description

/RMOT ON (TTL) Scanner Motor Control signal that switches the Scanner Motor on and off.

Low: On, High: Off

/SP11 (TTL) Print resolution selection signal that selects a ratio of frequency division of the clock signal.

/SP12 (TTL) Print resolution selection signal that selects a ratio of frequency division of the clock signal.

/SOS (TTL) Synchronization signal generated by the SOS PWBA that indicates the start of each scan.

5VDC-LD Laser Diode drive power causing the Laser Diode to emit laser light. This 5VDC supply to the LaserDiode is interrupted by the deactivation of the LD Switch in the CRU Sensor assembly.

VL1 Laser power control signal that determines (or adjusts) the current flowing through the Laser Diode(analog signal).

VL2 Laser power control signal that dete.rmines (or adjusts) the current flowing through the Laser Diode(analog signal).

MO Laser power monitor signal that feeds back the power of the laser light emitted by the Laser Diode(analog signal).

/P. DATA (TTL) Print image data (Low = Black dot, High = White dot).


Pin numbers and voltage levels for the MCU ⇔ ROS path

P11P112, P113, andP114 Signal Name

Signal Direction

M: MCU, L: LD

S: SOS

SM: Scanner Motor

R: ROS PWB TriggerHighLevel

LowLevel Note

13 P114-3 /RMOT ON (TTL) MCU⇒Scanner Motor Level TTL TTL

12 P114-5 /SP11 (TTL) MCU⇒ROS PWB Level TTL TTL

11 P114-6 /SP12 (TTL) MCU⇒ROS PWB Level TTL TTL

9 P113-2 /SOS (TTL) MCU⇐SOS Level TTL TTL

7 P112-1 5VDC-LD MCU⇒L - 5VDC 0V

5 P112-3 VL1 MCU⇒L - * * 0 ∼ 3.5 V

4 P112-4 VL2 MCU⇒L - * * 0 ∼ 3.5 V

3 P112-5 MO MCU⇐L - * * 0.7 ∼ 1.4 V

1 P112-7 /P. DATA (TTL) MCU⇒L Level TTL TTL


Selection of the print resolution with SP11 and SP12Resolution SP12 SP11

600/300 dpi ROS Assembly

600 dpi * H H

300 dpi H L


600 dpi * L L

360 dpi H L


600 dpi * L H

400 dpi L L


600 dpi * L H

480 dpi H L


480 dpi * H H

400 dpi L L


800 dpi * L L

600 dpi L H

* Factory setting


MCU ⇔ HVPS ⇔ EP CARTRIDGE (BCR and MAG.ROLL), BTR, and DETACK SAW

DRUM

DTS

TR

HVPS

MCU

DB

BCR

BTR

MAG.ROLLMAG.ROLL CR

24V

DC

RT

N

DB

-AC

/DB

-DC

ON

(L)

24V

DC

/CR

-DC

ON

(L)

24V

DC

/CR

-AC

ON

(L)

24V

DC

/DT

SO

N(L

)24

VD

C

/TR

(+)

ON

(L)

24V

DC

/TR

ON

(L)

24V

DC

TR

MO

-I

TR

MO

-V

BT

R-D

/A

DT

S-D

/A

CRU GUIDEASSEMBLY L

TRANS.CHUTEASSEMBLY L

DETACK SAW

CRU GUIDEASSEMBLY R

EP CARTRIDGE

P/J151

P/J151 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3

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

hc2m998F


Signal names for the MCU ⇔ HVPS pathSignal Name Description

DB-AC (TTL) Constant-frequency pulse signal that provides the source of oscillation for generating the ACcomponent of the DB (Development Bias) in the HVPS.

/DB-DC ON(L) 24VDC Control signal to switch the DC component of the DB on and off.

/CR-DC ON(L) 24VDC Control signal to switch the DC component of the CR on and off.

/CR-AC ON(L) 24VDC Control signal to switch the AC component of the CR on and off.

/DTS ON(L) 24VDC Control signal to switch the DTS on and off.

/TR(+) ON(L) 24VDC Control signal to switch the TR voltage between TR(+) and TR(-)

Low: TR(+), High: TR(-).

TR ON(L) 24VDC Control signal to switch the TR voltage on and off.

TR(+) or TR(-) is output according to the selection by the /TR(+) ON(L) signal.

TRMO-I Monitor signal of the TR(+) voltage when a constant-current output is selected by the ATDVC* (0∼ 5 VDC).

TRMO-V Monitor signal of the TR(+) current when a constant-voltage output is selected by the ATDVC*(0.4 ∼ 4.7 VDC).

BTR-D/A Control signal to select the TR(+) voltage as determined by the ATDVC.

DTS-D/A Control signal to select the DTS voltage as determined by the ATDVC.

* Active Transfer and Detack Voltage Control


Pin numbers and voltage levels for the MCU ⇔ HVPS path

P15 P151 Signal Name Signal Direction TriggerHighLevel

LowLevel Note

3 11 DB-AC MCU⇒HVPS Level TTL TTL

4 10 /DB-DC ON(L) 24VDC MCU⇒HVPS Level 24V 0V

5 9 /CR-DC ON(L) 24VDC MCU⇒HVPS Level 24V 0V

6 8 /CR-AC ON(L) 24VDC MCU⇒HVPS Level 24V 0V

7 7 /DTS ON(L) 24VDC MCU⇒HVPS Level 24V 0V

8 6 /TR(+) ON(L) 24VDC MCU⇒HVPS Level 24V 0V

9 5 TR ON(L) 24VDC MCU⇒HVPS Level 24V 0V

10 4 TRMO-I MCU⇐HVPS Level * * Analog

11 3 TRMO-V MCU⇐HVPS Level * * Analog

12 2 BTR-D/A MCU⇒HVPS Level * * Analog

13 1 DTS-D/A MCU⇒HVPS Level * * Analog


MCU ⇔ REG. CLUTCH, REG. SENSOR, PICK UPSOLENOID, and AUX TRAY NO-PAPER SENSOR

3

2

1

3

2

1

MCU

REGISTRATIONCLUTCHASSEMBLY

REGISTRATIONSENSOR

FEED SOLENOID(PICK UP SOLENOID)

AUX TRAYNO PAPERSENSOR

P.UP

SG

/REGIN(TTL)

PICK UP ON(L) 24VDC

24VDC

P.UP

SG

/NO PAPER0(TTL)

24VDC

REG. ON(L) 24VDC

P/J131

P/J13

P/J132

P/J935P/J135

P/J137P/J937P/J134

TRANSPORT CHUTE ASSEMBLY

1

2

3

4

5

6

7

8

9

10

4

3

2

1

3

2

1

2

1

3

2

1

1

2

3

1

2

hc2m999F


Signal names for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick Up Solenoid, and Aux TrayNo-Paper Sensor pathSignal Name Description

REG. ON(L) 24VDC Registration Clutch control signal. The Registration Clutch is activated when this signal isLow, and deactivated when High.

/REG. IN (TTL) Signal from the Registration Sensor. This signal is Low when the Registration Sensor isactivated.

/NO PAPER0 (TTL) Signal from the Aux Tray No-Paper Sensor (Front Tray). This signal is Low when the SINo-Paper Sensor is activated.

PICK UP ON(L) 24VDC Pick Up Solenoid control signal. The Pick Up Solenoid is activated when this signal is Low,and deactivated when High.


Pin numbers and voltage levels for the MCU ⇔ REG. Clutch, Reg. Sensor, Pick UpSolenoid, and Aux Tray No-Paper Sensor path

P13 Signal Name

Signal Direction

M: MCU,

RC: Reg. Clutch

RS: Reg. Sensor

AT: Aux Tray No-Paper Sen.

FS: Feed Solenoid TriggerHighLevel

LowLevel

2 P131-1 REG. ON(L) 24VDC M⇒RC Level TTL TTL

5 P132-1 /REG. IN (TTL) M⇐RS Level 24V 0V

8 P137-1 /NO PAPER0 (TTL) M⇐AT Level 24V 0V

10 P935-1 PICK UP ON(L) 24VDC M⇒FS Level 24V 0V


MCU ⇔ FEEDER1 PWB ⇔ FEED SOLENOID, CSTNO-PAPER SENSOR, and ELECTROMAGNETICCLUTCH

MCU

FEEDER1

FEED SOLENOIDCST NO PAPERSENSOR

ELECTROMAGNETICCLUTCH

A

B

C

CD

XZ

BE

AF

F

E

D

YW

24VDC

5VDC

4 3 2 1

1 2 3 4 5 6 7 8 9

3 2 1 1 2

2 1

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

PSIZE3 (TTL)

PSIZE1 (TTL)

/FEED3 ON(L) 24VDC

/FEED1 ON(L) 24VDC

/SIZE 3BIT(TTL)

/SIZE 1BIT(TTL)

/NO PAPER3 (TTL)

/NO PAPER1 (TTL)

FEEDER CHECK

5VDC

24VDC

RTN

SG

OPTION

/NO PAPER2 (TTL)

OPTION

/SIZE 2BIT(TTL)

/SIZE 4BIT(TTL)

/FEED2 ON(L) 24VDC

TURN (TTL)

PSIZE2 (TTL)

N.C.

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

N.C.

/TU

RN

ON

(L)

24V

DC

24V

DC

P.U

P

SG

/NO

PA

PE

R1

(TT

L)

24V

DC

/FE

ED

1O

N(L

)24

VD

C

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

24VDC

P/J203

P/J204

P/J904

P/J205

P/J206

P/J201

P/J202

P207P/J20

wXYZ

5VDC5VDC

SW1

PAPERSIZE

SWITCH

SIZESENSE

SW2

SW3

SW4

N.C.

hc2m800F


Signal names for the MCU ⇔ FEEDER1 PWB pathSignal Name Description

PSIZE3 (TTL) Selects the Paper Size Switches of Feeder 3. When this signal is High, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.


/FEED3 ON(L) 24VDC Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) is activatedwhen this signal is Low, and deactivated when High.


/SIZE 3BIT (TTL) Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 3 is activated.

/SIZE 1BIT (TTL) Signal from the Paper Size Switch 1 of the Feeder selected with PSIZE 1, 2 or 3 signal. Thissignal is Low when the Paper Size Switch 1 is activated.

/NO PAPER3 (TTL) Signal from the No Paper Sensor 3 (No Paper Sensor of the Feeder 3). This signal is Low whenthe No Paper Sensor 3 is activated.


FEEDER CHECK Signal that indicates the Feeder Configuration.

OPTION Reserved for option.




Signal Name Description



TURN (TTL) Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutchis activated when this signal is Low, and deactivated when High.



Pin numbers and voltage levels for the MCU ⇔ FEEDER1 PWB path

P20 P201 Signal Name

Signal Direction

M: MCU, F: Feeder1 TriggerHighLevel

LowLevel Note

A1 A11 PSIZE3 (TTL) M⇒F Level TTL TTL

A2 A10 PSIZE1 (TTL) M⇒F Level TTL 0V

A3 A9 /FEED3 ON(L) 24VDC M⇒F Level 24V 0V

A4 A8 /FEED1 ON(L) 24VDC M⇒F Level 24V 0V

A5 A7 /SIZE 3BIT (TTL) M⇐F Level TTL TTL

A6 A6 /SIZE 1BIT (TTL) M⇐F Level TTL TTL

A7 A5 /NO PAPER3 (TTL) M⇐F Level TTL TTL

A8 A4 /NO PAPER1 (TTL) M⇐F Level TTL TTL

A9 A3 FEEDER CHECK M⇐F Level * * Analog

B3 B10 OPTION M⇐F Level

B4 B9 /NO PAPER2 (TTL) M⇐F Level TTL TTL

B6 B7 /SIZE 2BIT (TTL) M⇐F Level TTL TTL

B7 B6 /SIZE 4BIT (TTL) M⇐F Level TTL TTL

B8 B5 /FEED2 ON(L) 24VDC M⇒F Level 24V 0V

B9 B4 TURN (TTL) M⇒F Level TTL TTL

B10 B3 PSIZE2 (TTL) M⇒F Level TTL TTL


MCU ⇔ MAIN MOTOR

M

MCU

MAIN MOTORP/J16

24VDC

RTN

/MOT REV (TTL)

MOT ALM (TTL)

/MAIN MOT(TTL)

1

2

3

4

5

hc2m801F


Signal names for the MCU ⇔ Main Motor pathSignal Name Description

/MOT REV (TTL) Control signal to switch the direction of the rotation of the Main Motor between Normal andReverse.

Low: Reverse direction, High: Normal direction

MOT ALARM (TTL) Main Motor monitor signal. Goes Low when the rotation of the Main Motor is abnormal.

/MAIN MOT (TTL) Main Motor Control Signal to switch the Main Motor on and off.

Pin numbers and voltage levels for the MCU ⇔ Main Motor pathP16 Signal Name Signal Direction Trigger High Level Low Level

3 /MOT REV (TTL) MCU⇒Main Motor Level TTL TTL

4 MOT ALARM (TTL) MCU⇐Main Motor Level TTL TTL

5 /MAIN MOT (TTL) MCU⇒Main Motor Level TTL TTL


MCU ⇔ TONER SENSOR

Signal names for the MCU ⇔ Toner Sensor pathSignal Name Description

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

Pin numbers and voltage levels for the MCU ⇔ Toner Sensor path

P22 P222 P922 P221 Signal Name Signal Direction TriggerHighLevel

LowLevel

4 1 4 4 /NO TONER (TTL) MCU⇐Toner Sensor Level TTL TTL

TONER SENSOR

MCU

24VDC

N.C.

SG

/NO TONER (TTL)

P/J22P/J221P/J222

P/J922

1

2

3

4

1

2

3

4

4

3

2

1

1

2

3

4

hc2m802F


MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCHor MCU ⇔ FUSER COVER SWITCH

MCUDUPLEX I/F PWB

1

2

1

2

2

1

2

1

2

1

2

1

COVERSWITCHCOVERSWITCH


91 2 10 3 11 4 12 5 13 6 14 7 15 8

P/J190

P/J190

P/J180

P/J18

J182

SG

/FCOVER OPEN (TTL)

/FCOVER OPEN (TTL)

OR

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1 hc2m803F


Signal names for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVER SWITCH pathSignal Name Description

/FCOVER OPEN (TTL) Signal from the Fuser Cover Switch. Goes Low when the Fuser Cover Switch isdeactivated (the Fuser Cover is open).

Pin numbers and voltage level for the MCU ⇔ DUPLEX I/F PWB ⇔ FUSER COVERSWITCH path

P18 P180 P190 Signal Name Signal Direction TriggerHighLevel

9 1 2 /FCOVER OPEN (TTL) MCU⇐Fuser Cover Switch Level TTL

Signal names for the MCU ⇔ FUSER COVER SWITCH pathSignal Name Description

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

Pin numbers and voltage level for the MCU ⇔ FUSER COVER SWITCH path

P18 P190 Signal Name Signal Direction TriggerHighLevel

8 1 /FCOVER OPEN (TTL) MCU⇐Fuser Cover Switch Level TTL


CONTROLLER ⇔ CONTROL PANEL

CONTROLLER

CONTROL PANEL

P/J411

P412

P/J421/LED 4 (TTL)

/LED 3 (TTL)

/LED 2 (TTL)

/LED 1 (TTL)

/KEY 1 (TTL)

/KEY 2 (TTL)

/KEY 3 (TTL)

/KEY 4 (TTL)

/KEY 5 (TTL)

/KEY 6 (TTL)

/KEY 7 (TTL)

/KEY 8 (TTL)

DB7 (TTL)

DB6 (TTL)

DB5 (TTL)

DB4 (TTL)

E (TTL)

RS (TTL)

5VDC

SG

20

19

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

hc2m804F


Signal names for the Controller ⇔ Control Panel pathSignal Name Description

/LED1 (TTL) ∼ /LED4 (TTL) LED switching signals. When these signals goes Low, the corresponding LEDsilluminate.

/KEY1 (TTL) ∼ /KEY8 (TTL) Key signals. When a key is pressed, the corresponding KEY signal goes Low.

DB4 ∼ DB7 (TTL) 4-bit data signals.

E (TTL) LCD enabling signal.

Low: Disable, High: Enable

16X2 TN LCD MODULE

To Controller +5v+5vP421- 2

P421- 1

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

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

SG

10

K

ERSDB7DB6DB5DB4KEY8KEY7KEY6KEY5KEY4KEY3KEY2KEY1

SW

1

SW

2

SW

3

SW

4

SW

5

SW

6

SW

7

SW

8

LE

D1

LE

D2

LE

D3

LE

D4

LED1LED2LED3LED4

15

0

¶

15

0

¶

15

0

¶

15

0

¶

DB

3D

B2

DB

1D

B0

R/W

VS

SV

0V

DD

+5V

47ALM

Ê0.1CER

Ê +

hc2m941F

Online

Menu

AttentionBuffer

CancelPrint

Item

Shift

Continue Enter*

Value +

-



RS (TTL) Register selecting signal which selects the command registers or the data registers.

Low: Command registers, High: Data registers

Pin numbers and voltage levels for the CONTROLLER ⇔ CONTROL PANEL path


Signal Direction

C: Controller

CP: Control Panel TriggerHighLevel

1∼4 20∼17 /LED4 (TTL) ∼ /LED1 (TTL) C⇒CP Level TTL

5∼12 16∼9 /KEY1 (TTL) ∼ /KEY8 (TTL) C⇐CP Level TTL

13∼16 8∼5 DB7(TTL) ∼ DB4 (TTL) C⇒CP Level TTL

17 4 E (TTL) C⇒CP Level TTL

18 3 RS (TTL) C⇒CP Level TTL


CONTROLLER ⇔ MCU and LVPS

CONTROLLER

LVPS

MCU

5VDC

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

1

2

/TPRINT (TTL)

SG

1

2

5VDC

SG

/TPRINT

/PRFD

/CCLK

/VDO

+5V

/CBSY

/STA

/TOP

/PPRDY

SG

SG

SG

SG

/CMD

/CPRDY

/START

/PCLK

/SBSY

/RDY

/BD

P411

P23

P/J31

P/J412

P/J126

1 2

hc2m805F


Signal names for the Controller ⇔ MCU pathSignal Name Description

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

Pin numbers and voltage levels for the Controller ⇔ MCU pathP/J31 Signal Name Signal Direction Trigger High Level Low Level

A1 /TPRINT MCU⇐Controller Level TTL TTL


Signals between the Controller and the MCU

The table below lists the signals that are used between the Controller and the MCU.

PIN SIGNAL DIRECTION DESCTIPTION

A9 /PPRDY MCU⇒Controller Printer Power Ready: Goes Low when the printer is powered onand completes initialization. The printer is in ON-LINE mode.

A8 /TOP MCU⇒Controller Top of Paper: Vertical synchronization signal.

A7 /STA MCU⇒Controller Status: The MCU sends a Status serially in synchronism with/PCLK (/CCLK when the Controller requests the MCU to use it).

A6 /CBSY MCU⇐Controller Command Busy: The Controller holds this signal Low whilesending a Command.

A4 /VDO MCU⇐Controller Video: The Controller sends print data to the MCU, synchronizingthe beginning of each page and each line (raster line) of the printdata with /TOP and /BD, respectively. The transmission ratedepends on the print resolution.v 300dpi: 4.41769 MHz/480dpi: 11.30930 MHzv 360dpi: 6.36148 MHz/600dpi: 17.67078 MHzv 400dpi: 7.85368 MHz/800dpi: 31.41472 MHz

A3 /CCLK MCU⇐Controller Controller Clock: Clock signal that is supplied by the Controller andused for synchronous transmission of a Command by theController. The MCU uses this clock signal for transmission of aStatus when requested to use it by the Controller.

A2 /PRFD MCU⇐Controller Prefeed: When the MCU receives this signal, it feeds a sheet ofpaper to just before the Registration Sensor (pre-fed position), andwaits for /START.



B10 /BD MCU⇒Controller Beam Detect: Horizontal synchronization signal. The Controllerbegins to send the video data for one scan line when it receivesthis signal. /BD is sent at the following time intervals.v 300 dpi: 930.4 ms/480 dpi: 581.5 msv 360 dpi: 775.3 ms/600 dpi: 465.2 msv 400 dpi: 697.8 ms/800 dpi: 348.9 ms

B9 /RDY MCU⇒Controller Ready: The MCU holds this signal Low when it can accept /PRFDand /START. When /RDY is High, /PRFD and /START are ignored.

The MCU raises /RDY High when the printer is in one of thefollowing states:1. Call2. Pause/Diagnostic3. Wait4. Misprint5. /PPRDY at High

B8 /SBSY MCU⇒Controller Status Busy: The MCU holds this signal Low when it is sending aStatus.

B7 /PCLK MCU⇒Controller Printer Clock: Clock signal that the MCU supplies and uses forsynchronized transmission of a Status.

B6 /START MCU⇐Controller START: Orders the printer to start the print operation. This signal isvalid only when /RDY is Low.



B5 /CPRDY MCU⇐Controller Controller Power Ready: Goes Low when the Controller is poweredon and completes initialization. When this signal goes High, theprinter resets to the powered-on state.

v Printer state⇒Standby (ROS: Off, Fuser: On)

When the printer is in the Printing state or the Print Ready state,the printer returns to the Standby state immediately or after theprint operation is completed. When in the Pause state (ROS: Off,Fuser: Off), the printer returns to the Standby state except whenthe Fan is stopped.

(continued)

B5 /CPRDY MCU⇐Controller v Resolution⇒Higher resolution

When the printer has two resolutions and the lower resolution isselected, the resolution returns to the Higher resolution.

v Paper size mismatch detection⇒Enabled

v Fuser temperature⇒Normal temperature

When the high temperature for thick paper is selected, the fusertemperature returns to the normal temperature.

B4 /CMD MCU⇐Controller Command: The Controller sends a Command serially insynchronism with /CCLK.


MCU ⇔ Feeder PWB ⇔ Feeder PWB ⇔ Feeder PWB ⇔Feed Solenoid, No Paper Sensor, and ElectromagneticClutch

MCU PWB FEEDER PWB

FEEDER PWB

FEEDER ASSY FEED SOLENOIDCST NO PAPERSENSOR

ELECTROMAGNETICCLUTCH AUX.

G

G

H

H

I

I

X

Z

M

M

K

K

J

J

Y

W

24VDC

5VDC

4 3 2 1

1 2 3 4

1 2 3 4 5 6 7 8 9

3 2 1 1 2

2 1

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

N.C.

N.C.

24V

DC

TU

RN

ON

(L)

24V

DC

P.U

P

SG

/ NO

PA

PE

R2

(TT

L)

24V

DC

/ FE

ED

2O

N(L

)24

VD

C

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

P/J203

P/J204

P/J904

P/J205

P/J206

P/J906

P/J201

P/J202

P207

P/J202

P/J20 P/J201 P/J207

A

B

C

CD

BE

AF

F

E

D

24VDC

wXYZ

5VDC5VDC

SW1

PAPERSIZE

SWITCH

SIZESENSE

SW2

SW3

SW4

1st Tray

2nd Tray (Optional)

N.C.

PSIZE2 (TTL)

N.C.

/FEED2 ON(L) 24VDC

/SIZE 3BIT(TTL)

/SIZE 1BIT(TTL)

N.C.

/NO PAPER2 (TTL)

FEEDER CHECK

SVDC

24VDC

RTN

SG

OPTION

/NO PAPER3 (TTL)

OPTION

/SIZE 2BIT(TTL)

/SIZE 4BIT(TTL)

/FEED3 ON(L) 24VDC

TURN (TTL)

PSIZE3 (TTL)

N.C.

hc2m816F


FEEDER PWB

FEEDER ASSY FEED SOLENOIDCST NO PAPERSENSOR

ELECTROMAGNETICCLUTCH AUX.

G

G

H

H

I

I

X

Z

M

M

K

K

J

J

Y

W

24VDC

5VDC

4 3 2 1

1 2 3 4

1 2 3 4 5 6 7 8 9

3 2 1 1 2

2 1

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

N.C.

N.C.

24V

DC

TU

RN

ON

(L)

24V

DC

P.U

P

SG

/ NO

PA

PE

R3

(TT

L)

24V

DC

/ FE

ED

3O

N(L

)24

VD

C

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

P/J203

P/J204

P/J904

P/J205

P/J206

P/J906

P/J201

P/J202

P207

24VDC

wXYZ

5VDC5VDC

SW1

PAPERSIZE

SWITCH

SIZESENSE

SW2

SW3

SW4

N.C.

PSIZE2 (TTL)

N.C.

/FEED1 ON(L) 24VDC

/SIZE 3BIT(TTL)

/SIZE 1BIT(TTL)

N.C.

/NO PAPER1 (TTL)

FEEDER CHECK

SVDC

24VDC

RTN

SG

OPTION

/NO PAPER2 (TTL)

OPTION

/SIZE 2BIT(TTL)

/SIZE 4BIT(TTL)

/FEED2 ON(L) 24VDC

TURN (TTL)

PSIZE2 (TTL)

N.C.

MCU PWB FEEDER PWB FEEDER PWB

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

A1

A2

A3

A4

A5

A6

A7

A8

A9

A10

A11

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A11

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B12

B11

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

A10

A9

A8

A7

A6

A5

A4

A3

A2

A1

B10

B9

B8

B7

B6

B5

B4

B3

B2

B1

P/J202

P/J20 P/J20P/J201 P/J201 P/J207

AA

BB

CC

CC DD

BB EE

AA FF

FF

EE

DD

1st Tray2nd Tray(Optional)

3rd Tray (Optional)

hc2m807F


Signal names for the Feeder PWB ⇔ Feeder PWB pathSignal Name Description

PSIZE2 (TTL) Selects the Paper Size Switches of Feeder 2. When this signal is HIGH, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 2 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.

/FEED2 ON(L) 24VDC Feed Solenoid 2 control signal. The Feed Solenoid 2 (Feed Solenoid of the Feeder 2) isactivated when this signal is LOW, and deactivated when HIGH.

/SIZE 3BIT (TTL) Signal from the Paper Size Switch 3 of the Feeder selected with the PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 3 is activated.

/SIZE 1BIT (TTL) Signal from the Paper Size Switch 1 of the Feeder selected with the PSIZE2 or 3 signal. Thissignal is LOW when the Paper Size Switch 1 is activated.


FEEDER CHECK Signal that indicates the Feeder Configuration.


/SIZE 2BIT (TTL) Signal from the Paper Size Switch 2 of the Feeder selected with PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 2 is activated.

/SIZE 4BIT (TTL) Signal from the Paper Size Switch 4 of the Feeder selected with PSIZE 2 or 3 signal. Thissignal is LOW when the Paper Size Switch 4 is activated.

/FEED3 ON(L) 24VDC Feed Solenoid 3 control signal. The Feed Solenoid 3 (Feed Solenoid of the Feeder 3) isactivated when this signal is LOW, and deactivated when HIGH.

TURN (TTL) Control signal to actuate and deactuate the Electromagnetic Clutch. The Electromagnetic Clutchis activated when this signal is LOW, and deactivated when HIGH.

PSIZE3 (TTL) Selects the Paper Size Switches of Feeder 3. When this signal is HIGH, the On or Off states ofthe Paper Size Switches 1 to 4 of the Feeder 3 are input to the MCU on the signal lines SIZE1BIT to SIZE 4BIT.


Pin numbers and voltage levels for the Feeder PWB (Feeder1) ⇔ Feeder PWB (Feeder2)path

P202(Feeder1)

P201(Feeder2) Signal Name

Signal Direction

F1: Feeder1

F2: Feeder2 TriggerHighLevel

LowLevel Note

A10 A10 PSIZE2 (TTL) F1⇒F2 Level TTL TTL

A8 A8 /FEED2 ON(L) 24VDC F1⇒F2 Level 24V 0V

A7 A7 /SIZE 3BIT (TTL) F1⇐F2 Level TTL TTL


A4 A4 /NO PAPER2 (TTL) F1⇐F2 Level TTL TTL

A3 A3 FEEDER CHECK F1⇐F2 Level * * Analog

B7 B9 /NO PAPER3 (TTL) F1⇐F2 Level TTL TTL

B5 B7 /SIZE 2BIT (TTL) F1⇐F2 Level TTL TTL


B3 B5 /FEED3 ON(L) 24VDC F1⇒F2 Level 24V 0V

B2 B4 TURN (TTL) F1⇒F2 Level TTL TTL

B1 B3 PSIZE3 (TTL) F1⇐F2 Level TTL TTL

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


Pin numbers and voltage levels for the Feeder PWB (Feeder2) ⇔ Feeder PWB (Feeder3)path

P202(Feeder2)

P201(Feeder3) Signal Name

Signal Direction

F2: Feeder2

F3: Feeder3 TriggerHighLevel

LowLevel Note

A10 A10 PSIZE3 (TTL) F2⇒F3 Level TTL TTL

A8 A8 /FEED3 ON(L) 24VDC F2⇒F3 Level 24V 0V



A4 A4 /NO PAPER3 (TTL) F2⇐F3 Level TTL TTL

A3 A3 FEEDER CHECK F2⇐F3 Level * * Analog



B3 B5 /FEED3 ON(L) 24VDC F2⇒F3 Level 24V 0V

B2 B4 TURN (TTL) F2⇒F3 Level TTL TTL

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


Detection of the Feeder configuration through the FEEDER CHECK signal

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

FEEDER PWB

FEEDERCHECK(TTL)

RF

RM

RF RF

TRAY 1

FEEDER PWB

TRAY 2

FEEDER PWB

TRAY 3

5VDC

SG

MCU PWB

DetectionCircuit

hc2m814F


Feeder Configuration Feeder 1 Feeder 2 Feeder 3 Voltage (Nominal)

Feeder1 (standard Feeder) not connected 0 VDC

Feeder1 only O 1.60 VDC

One optional Feeder added O O 2.42 VDC

Two optional Feeders added O O O 2.93 VDC


MCU ⇔ Duplex I/F PWB ⇔ Duplex PWB and FuserCover Switch Duplex PWB ⇔ Dup Stack Sensor, DupCover Switch1, Dup Cover Switch2, Duplex PassSensor, Duplex Motor, and Offset Motor

M

M

MCU PWB

DUPLEXPWB

DUPLEXPWB

DUPLEX UNIT

DUPLEX I/F PWB

DUPLEXMOTOR

DUP STACKSENSOR

DUP COVERSWITCH 1

DUP COVERSWITCH 2

DUPLEX PASSSENSOR

OFFSETMOTOR


P/J190

P/J180

P/J18

P/J182

2 1

1 2

DUPLEXMOTOR

CONTROL

OFFSETMOTORCONTROL

5VDC

5VDC

24VDC

P/J192

P/J184

P/J187

P/J186

P/J183

P/J193

P/J198

P/J197

P/J195

P/J196

DUP B

DUP / A

DUP A

DUP / B

RTN

SG

24VDC

N.C.

/ DUP COVER (TTL)

5VDC

/ FULL (TTL)

/ OCT REV (TTL)

/ OCT ON (TTL)

/ DUP SNS (TTL)

P.UP

SG

/ FULL (TTL)

SG

/ DUP COV 1 (TTL)

MOT +

MOT -

/ DUP SNS (TTL)

SG

A

B

24VDC

24VDC

/ A

/ B

/ DUP COV 2 (TTL)

/ DUP COV (TTL)

hc2m826F

1

9

2

10

3

11

4

12

5

13

6

14

7

15

8

1

1

2

3

4

5

6

7

8

9

10

11

12

13

14

1

2

3

4

5

6

7

8

1

2

3

4

5

6

7

1

2

3

2

1

2

1

1

2

3

4

5

6

1

2

1

2

1

2

2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 1813


Signal names for the Duplex I/F PWB ⇔ Duplex PWB pathSignal Name Description

DUP B Duplex Motor exciting signal.

DUP /A Duplex Motor exciting signal.

DUP A Duplex Motor exciting signal.

DUP /B Duplex Motor exciting signal.

/DUP COVER (TTL) Signal from the Dup Cover Switches 1 and 2. This signal is LOW when both the Dup CoverSwitches 1 and 2 are closed and High when the Dup Cover Switch1 or the Dup Cover Switch2 isopen.

/FULL Signal through the Dup Stack Sensor. This signal is LOW when the Dup Stack Sensor isactivated by the stack of delivered printed sheets higher than the predetermined height.

This signal is also used to detect whether the Duplex Unit is installed when printer power isswitched on.

/OCT REV (TTL) Control signal to switch the direction of rotation of the Offset Motor between Normal and Reverse.

LOW: Reverse direction, HIGH: Normal direction

/OCT ON (TTL) Offset Motor Control Signal to switch the Offset Motor on and off.

/DUP SNS (TTL) Signal from the Duplex Pass Sensor. This signal is LOW when the Duplex Pass Sensor isactivated by the paper.


Pin numbers and voltage levels for the Duplex I/F PWB ⇔ Duplex PWB path


Signal Direction

DIF: Dup I/F PWB

D: Duplex PWB TriggerHighLevel Low Level

1 1 DUP B DIF⇒D Level

9 2 DUP /A DIF⇒D Level

2 3 DUP A DIF⇒D Level

10 4 DUP /B DIF⇒D Level

5 9 /DUP COVER (TTL) DIF⇐D Level TTL TTL

6 11 /FULL DIF⇐D Level * 0V

14 12 /OCT REV (TTL) DIF⇒D Level TTL TTL

7 13 /OCT ON (TTL) DIF⇒D Level TTL TTL

15 14 /DUP SNS (TTL) DIF⇐D Level TTL TTL

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

Signal names for the Duplex PWB ⇔ Offset Motor pathSignal Name Description

MOT+, MOT- Offset Motor drive power.

Normal rotation: When MOT+ is 24 VDC and MOT- is 0 VDC.

Reverse rotation: When MOT+ is 0 VDC and MOT- is 24 VDC.


Pin numbers and voltage levels for the Duplex PWB ⇔ Offset Motor path


Signal Direction

D: Duplex PWB

OM: Offset Motor Trigger High Level Low Level

1 1 MOT+ D ⇔ OM Level 24 VDC 0 V

2 2 MOT- D ⇔ OM Level 24 VDC 0 V


HCF LVPS⇔ Components, HCF LVPS ⇔ FEEDER PWB

RIGHT HAND COVEROPEN SWITCH

LEFT HAND COVEROPEN SWITCH

TRANSPORT MOTOR

SENSOR

TRAY SET SENSOR 1

PAPER LEVEL SENSOR

ENCODER

FEEDMOTORCONTROL

NO PAPER SENSOR

UPPER LIMIT SENSOR

TRAY SET SENSOR 2

SIZE SENSOR

NEAR EMPTY SENSOR

LOWER POSITION SENSOR

LIFT UP MOTOR

P/J:M1

P/J:S2

P/J:S7

P/J:S11

P/J:S3

P/J:P1

P/J:S1

P/J:XS4

P/J:P2

P/J:S10

P/J:S6

P/J:S12

P/J:S9

P/J:M2

P/J:S8

LIFT UPMOTORCONTROL

CPU

SG

P/J:XS3RXDTXDSGSG

FEEDER CHECK

BaseEngine

or

2ND TRAY

(+)( - )

13

13

13

21

13

321

54

123

123

1234

12

123

12

12

GNDGND

FG

DC21

DC22

DC22

SWHD

SGSWPL(TTL)

SGSWPSZ(TTL)

DC21SWHU1

SWHU1SWHU2

+5VDC

LSPE(TTL)

SG

DC11DC12

+5VDC

ENCOD(TTL)

SG

+5VDC

LSPL(TTL)

SG

SWCPR(TTL)

SG

+5VDC

LSPEX(TTL)

SG

SM1

SM2

SM3

SM4

SWDO1(TTL)

SWDO(TTL)

SWDO1(TTL)

SG

FEED MOTOR

141612139

12345

P/J:XS110912

56

78

34

P/J:XS2

1211

2526

12

345

678

222324

910

131415

18192021

1617

2728

TRANSPORTMOTORCONTROL

MAIN SWITCHAC to DC

SERVICE CONNECT

AC INLET

LVPS

M

M

M

This is an internal wiring of the FEED ROLLER KIT,therefore the P/J No. and Pin No. are omitted.hc2m089F


Signal names for the HCF LVPS ⇔ ComponentsSignal Name Description

DC21, DC22 DC21, DC22

Elevator Motor drive power

Elevator rotation: When DC21 is 0VDC and DC22 is more then 22VDC.

Lift down rotation: When DC21 is more then 22VDC and DC22 is 0VDC.

SWHD SWITCH HAZARD DOWN

This switch interrupts the motor current if the elevator is in the down position (fill position).

SWPL (TTL) SWITCH PAPER LOW

This signal indicates the Paper low stack.

LSPE (TTL) LIGHT SENSOR PAPER END

This signal indicates if the last sheet fed.

ENCOD (TTL) ENCODER SIGNAL

This signal controls the Feed Motor. It works as speed regulator.

DC11, DC12 DC11, DC12

Feed Motor drive power, 0 / 24VDC (PWM SIGNAL)

LSPL (TTL) LIGHT SENSOR PAPER LEVEL

This signal shows if the paper stack is in feed position.

SWCPR (TTL) SWITCH CARRIAGE PRESENT

This signal indicates if the carriage is in or out.



LSPEX (TTL) LIGHT SENSOR PAPER EXIT

This signal indicates that a paper is in the transport.

SM1 TRANSPORT MOTOR/A

Transport Motor exciting signal.

SM2 TRANSPORT MOTOR A


SM3 TRANSPORT MOTOR/B


SM4 TRANSPORT MOTOR B


SWDO (TTL)

SWDO1 (TTL)

SWITCH DOOR OPEN

This signal indicates an open rear cover.

SWHU1

SWHU2

SWITCH HAZARD UP

This safety switch interrupts the motor current if the Paper Level Sensor does not work and theelevator moves up too much.

SWPSZ (TTL) SWITCH PAPER SIZE

This signal displays the used paper size in the HCF.


Signal names for the HCF LVPS ⇔ FEEDER PWBSignal Name Description

TXD TRANSMITTED DATA

Data connection Base Engine to HCF.

RXD RECEIVED DATA

Data connection HCF To Base Engine.

FEEDER CHECK FEEDER CHECK

Signal that indicates the Feeder / HCF Configuration.


Pin numbers and voltage levels for the HCF LVPS ⇔ Components

P: P: Signal Name Signal Direction TriggerHighLevel Low Level

XS1-1 M1-(+) DC21 Floating Signal (see note 1) LEVEL 0V 24V

XS1-2 M1-(-) DC22 Floating Signal (see note 1) LEVEL 24V 0V

XS1-3 S1-1 SG Power - 0V

XS1-4 S1-3 SWPL (TTL) Near Empty Sensor → LVPS LEVEL TTL TTL

XS1-5 S2-1 DC22 Floating Signal (see note 1) LEVEL 24V 0V

XS1-6 S2-3 SWHD Floating Signal (see note 1) LEVEL 24V 0V


XS1-8 S3-3 SWPSZ (TTL) Paper Size Sensor → LVPS LEVEL TTL TTL

XS1-9 SG Power - 0V

XS1-10 SG Power - 0V

XS2-1 P1-5 DC11 LVPS → Feed Motor LEVEL 24V 0V (seenote 2)

XS2-2 P1-4 DC12 LVPS → Feed Motor LEVEL 24V 0V (seenote 2)

XS2-3 P1-3 +5V Power - 5V

XS2-4 P1-2 LSPE (TTL) No Paper Sensor → LVPS LEVEL TTL TTL

XS2-5 P1-1 SG Power - 0V

XS2-6 P2-1 +5V Power - 5V

XS2-7 P2-2 ENCOD (TTL) Encoder → LVPS LEVEL TTL TTL

XS2-8 P2-3 SG Power - 0V

XS2-9 S6-1 SWCPR (TTL) Tray Set Sensor 1 → LVPS LEVEL TTL TTL




XS2-11 S7-1 SWHU1 Floating Signal (see note 1) LEVEL 24V 0V

XS2-12 S7-2 DC21 Floating Signal (see note 1) LEVEL 24V 0V

XS2-13 S8-1 +5V Power - 5V

XS2-14 S8-2 LSPEX (TTL) Sensor → LVPS LEVEL TTL TTL


XS2-16 S9-1 SWDO1 Left Hand Cover OpenSwitch → Right Hand CoverOpen Switch

LEVEL TTL TTL


XS2-18 M2-1 SM1 LVPS → Transport Motor LEVEL 24V 0V (seenote 3)




XS2-22 S10-1 +5V Power - 5V

XS2-23 S10-2 LSPL (TTL) Paper Level Sensor → LVPS LEVEL TTL TTL






XS2-27 S12-1 SWDO1 Left Hand Cover OpenSwitch → Right Hand CoverOpen Switch

LEVEL TTL TTL

XS2-28 S12-2 SWDO Right Hand Cover OpenSwitch → LVPS

LEVEL TTL TTL

Notes:1. This signal is used to stop the Elevator Motor when it is not responding. It is connected to the Drive Power cable and the

Serial port (no direction).2. PWM (Pulse Width Modulation) Signal3. Rectangle Signal


Chapter 5. LocationsQuick Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361Covers and Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362Electrical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364

Clutches, Solenoids, Motors, and Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367Printed Wiring Boards (PWBs). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .380Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386

Mechanical and Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390


Quick PathTo... Location Tables with Links to Illustrations, to the Parts

Catalog, to Wiring and Pinout Diagrams, and to Removals

Assemblies Table 59 on page 362

Clutches Table 60 on page 364

Connectors Table 61 on page 367

Covers Table 59 on page 362

Fans Table 60 on page 364

Mechanical Table 65 on page 390

Motors Table 60 on page 364

Paper Path Figure 23 on page 392

Printed Wiring Boards (PWBs) / Power Supplies Table 62 on page 380

Sensors Table 63 on page 384

Solenoids Table 60 on page 364

Switches Table 64 on page 386

Chapter 5. Locations 361

Covers and AssembliesTable 59. Assemblies

Unit Cover or Assembly Figure Parts Catalog Asm.– Index

Printer

Operator Panel Fig. 5, p. 363 1–18, p. 548

Top Cover Fig. 5, p. 363 1–14, p. 548

Tray 1 Fig. 5, p. 363 2, p. 550

Auxiliary Tray Fig. 5, p. 363 5, p. 557

Fuser Cover Fig. 5, p. 363 8–1, p. 564

Rear Cover Fig. 5, p. 363 3–5, p. 553

Serial Number Fig. 5, p. 363

Power Cord Socket Fig. 5, p. 363 12–4, p. 572

Power Switch Fig. 5, p. 363 12–4, p. 572

Side Cover Fig. 5, p. 363 1–10, p. 548

Duplex Duplex Unit Fig. 5, p. 363 30, 31, p. 652, 655

Duplex Covers Fig. 5, p. 363 30-5, 30-6, p. 652

Trays Tray 2/3 Fig. 5, p. 363 20, 21, p. 697, 700

2000-Sheet Input Drawer Fig. 5, p. 363 40, 41, 42, p. 774, 776, 778


500-sheet paper tray(Tray 1)

Auxiliarytray

Operator panel

PowerswitchPower

cord socket

Printercontrollerboard

500-sheetpaper trays(Tray 2/Tray 3)(optional)

Duplex unit(optional)

Duplex covers

Top cover Fusercover

Rearcover

Side cover

2000-sheetinput drawer(optional)

X12345

Serialnumber

hc2m221F

Figure 5. Covers and Assemblies


Electrical Components

Clutches, Solenoids, Motors, and FansTable 60. Clutches, Solenoids, Motors, and Fans

Unit Clutch, Solenoid, Motor, or Fan Figure / Reference Parts Catalog Asm.–Index

WiringDiagram

PinoutDiagram

Printer

CL1 Registration Clutch Fig. 6, p. 365 / 6 10–9, p. 570 p. 322 p. 324

CL2 Electromagnetic (Turn) Clutch Fig. 6, p. 365 / 5 4–9, p. 555 p. 325 p. 328

SL1 Feed Solenoid Fig. 6, p. 365 / 4 4–8, p. 555 p. 325 p. 328

SL2 Pick Up Solenoid Fig. 6, p. 365 / 2 6–17, p. 559 p. 322 p. 324

Fan Fig. 6, p. 365/ 1 12–3, p. 575 p. 311 p. 311

Main motor Fig. 6, p. 365/ 3 10–6, p. 570 p. 329 p. 330

Trays CL2 Tray 2/3 Electromagnetic (Turn)Clutch

Fig. 7, p. 366 / 7 21–19, p. 700 p. 342 p. 342

SL1 Tray 2/3 Feed Solenoid Fig. 7, p. 366 / 8 21–18, p. 700 p. 342 p. 342

Duplex Offset motor Fig. 8, p. 366/ 9 30–21, p. 652 p. 349 p. 352

Duplex motor Fig. 8, p. 366/ 10 31–23, p. 655 p. 349 p. 351

HCF Elevator motor Fig. 9, p. 367/ 11 41–10, p. 776 p. 353 p. 357

Feed motor Fig. 9, p. 367/ 12 42–28, p. 778 p. 353 p. 357

Transport motor Fig. 9, p. 367/ 13 42–21, p. 778 p. 353 p. 357


hc2m222F

23

1

456

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


HC2M122F

7 8

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

HC2M118F

10

9

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


ConnectorsTable 61. Connectors, Printer

Connector WiringDiagram

PinoutDiagramP/J Figure / Grid From... To...

11 Fig. 11, p. 375 / C4 MCU PWB... LVPS Assembly p. 311 p. 311

12 Fig. 11, p. 375 / B3 MCU PWB... ROS Assembly p. 315 p. 317

13 Fig. 11, p. 375/ B4 MCU PWB... High Harness Assembly (Registration Clutch,Registration Sensor, No Paper Sensor, and Feed Solenoid)

p. 322 p. 324

14 Fig. 11, p. 375 / B3 MCU PWB... High Harness Assembly (Full Stuck Sensor,Temperature Sensor, and Exit Sensor)

p. 313 p. 314

15 Fig. 11, p. 375 / B4 MCU PWB... HVPS Assembly p. 319 p. 321

16 Fig. 11, p. 375 / B3 MCU PWB... Main Motor p. 329 p. 330

11

12

13

hc2m130F

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


Table 61. Connectors, Printer (continued)



17 Fig. 11, p. 375 / C2 MCU PWB... CRU Sensor Assembly p. 315 p. 317

18Fig. 11, p. 375 / B3 MCU PWB... Duplex Interface PWB

p. 332 p. 332Fig. 11, p. 375 / B3 MCU PWB... Fuser Cover Switch (if no Duplex Interface

PWB)

19 Fig. 11, p. 375 / B4 MCU PWB... diagnostic tool console panel (open connector) p. 310 p. 310

20 Fig. 11, p. 375 / C4 MCU PWB... Feeder PWB p. 325 p. 328

21 Fig. 11, p. 375 / C4 MCU PWB... Interlock Switch p. 311 p. 311

22 Fig. 11, p. 375 / B4 MCU PWB... Toner Sensor p. 331 p. 331

23 Fig. 11, p. 375 / B4 Open connector for producing test print output (two pins) p. 310 p. 310

31 Fig. 11, p. 375 / B4 MCU PWB... ESS PWB p. 337 p. 338

112 Fig. 11, p. 375 / A2 ROS Assembly (LD Assembly)... MCU PWB p. 315 p. 317

113 Fig. 11, p. 375 / A1 ROS Assembly (SOS PWB)... MCU PWB p. 315 p. 317

114 Fig. 11, p. 375 / A2 ROS Assembly (Scanner Assembly)... MCU PWB p. 315 p. 317

121 Fig. 11, p. 375 / B3 LVPS Assembly... LMCU PWB p. 311 p. 311

122 Fig. 11, p. 375 / C3 LVPS Assembly... Fan p. 311 p. 311

123 Fig. 10, p. 373 / B3 LVPS Assembly... Interlock Switch p. 311 p. 311

124 Fig. 11, p. 375 / C2 LVPS Assembly... High Harness Assembly Heater Rod p. 311 p. 311

126 Fig. 11, p. 375 / C3 LVPS Assembly... ESS p. 337 p. 338

127 Fig. 11, p. 375 / C3 Open connector (plug) on LVPS Assembly board p. 311 p. 311





131 Fig. 11, p. 375 / C1 Registration Clutch Assembly... High Harness Assembly(MCU PWB)

p. 322 p. 324

132 Fig. 10, p. 373 / C3 Registration Sensor... High Harness Assembly (MCU PWB) p. 322 p. 324

134 Fig. 10, p. 373 / C3 MSI No Paper Sensor... MCU PWB p. 322 p. 324

135 Fig. 10, p. 373 / C2 Feed Solenoid... High Harness Assembly (MCU PWB) p. 322 p. 324

137 Fig. 10, p. 373 / C2 MSI Bracket Assembly (MSI N/P Harness)... High HarnessAssembly (MCU PWB)

p. 322 p. 324

142 Fig. 10, p. 373 / A2 Fuser Assembly (Heater Assembly)... Transport ChuteAssembly (High Harness Assembly (MCU PWB)

p. 313 p. 314

143 Fig. 10, p. 373 / A3 Temperature Sensor Assembly... Fuser Harness (MCUPWB)

p. 313 p. 314

144 Fig. 10, p. 373 / A3 Exit Sensor... MCU PWB p. 313 p. 314

145 Fig. 10, p. 373 / A3 Full Stuck Sensor... MCU PWB p. 313 p. 314

151 Fig. 11, p. 375 / B3 HVPS Assembly... MCU PWB p. 319 p. 321

171 Fig. 11, p. 375 / A1 CRU Sensor Assembly internals... MCU PWB p. 315 p. 317

180 Fig. 11, p. 375 / A1 Duplex Interface PWB... Fuser Cover Switch p. 332 p. 333

182 Fig. 11, p. 375 / C4,Fig. 13, p. 377 / B2 Duplex Interface PWB... Duplex Unit (Duplex Cable) p. 349 p. 351

183 Fig. 13, p. 377 / B2 Duplex Cable... Duplex PWB p. 349 p. 351

184 Fig. 13, p. 377 / A2 Duplex Sensor Harness... Duplex PWB p. 349 p. 349

186 Fig. 13, p. 377 / A2 Offset Motor... Duplex PWB p. 349 p. 352





187 Fig. 13, p. 377 / A2 Duplex Motor Harness... Duplex PWB p. 349 p. 349

190 Fig. 11, p. 375 / C4 Fuser Cover Switch... Duplex Interface PWB p. 332 p. 333

192 Fig. 13, p. 377 / A3 Duplex Sensor Harness... Duplex Stack Sensor p. 349 p. 349

193 Fig. 13, p. 377 / A2 Duplex Sensor Harness... Duplex Cover Switch 1 p. 349 p. 349

195 Fig. 13, p. 377 / A4 Duplex Motor Harness... Duplex Pass Sensor p. 349 p. 349

196 Fig. 13, p. 377 / A2 Offset Motor p. 349 p. 352

197 Fig. 13, p. 377 / A3 Duplex Motor Harness... Duplex Motor p. 349 p. 349

198 Fig. 13, p. 377 / B2 Duplex Sensor Harness... Duplex Cover Switch 1 p. 349 p. 349

201 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / A3 Feeder PWB... MCU PWB p. 342 p. 345

202 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / A3 Feeder PWB... Tray Lower1 Harness p. 342 p. 346

203 Fig. 11, p. 375 / B3,Fig. 12, p. 376 / B3

Feeder PWB... Feeder Harness (Turn Clutch, No PaperSensor, and Feed Solenoid)

p. 342 p. 342

204 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B2 Feed Solenoid... MCU PWB p. 342 p. 342

205 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B3 Cassette No Paper Sensor... MCU PWB p. 342 p. 342

206 Fig. 11, p. 375 / C1,Fig. 12, p. 376 / B2,

Electromagnetic Clutch... MCU PWB p. 342 p. 342





207Fig. 10, p. 373 / C1,Fig. 12, p. 376 / A3,B3

Tray Lower1 Harness... option’s Feeder Assembly (Plugs) p. 342 p. 342

221 Fig. 10, p. 373 / C3 Toner Sensor... MCU PWB p. 331 p. 331

222 Fig. 10, p. 373 / C2 MSI Bracket Assembly (Toner Sensor Harness)... TonerRelay Harness (MCU PWB)

p. 331 p. 331

421 Fig. 10, p. 373 / A1 Console Assembly... Controller p. 334 p. 336

904 Fig. 11, p. 375 / C2,Fig. 12, p. 376 / B2 Feed Solenoid... MCU PWB p. 342 p. 342

906 Fig. 12, p. 376 / B2 MCU PWB ... Electromagnetic Clutch p. 342 p. 342

922 Fig. 10, p. 373 / C2 Toner Sensor... MCU PWB p. 331 p. 331

935 Fig. 10, p. 373 / C2 Feed Solenoid... MCU PWB p. 322 p. 324

937 Fig. 10, p. 373 / C2 MSI No Paper Sensor... MCU PWB p. 322 p. 324

942 Fig. 10, p. 373 / A2 Fuser Harness... Heater Assembly p. 313 p. 314

943 Fig. 10, p. 373 / A3 Fuser Harness internal connector p. 313 p. 314

CR Fig. 11, p. 375 / A3 HVPS Assembly... CRU Guide Assembly Left (Power supplyfor BCR)

p. 319 p. 321

DB Fig. 11, p. 375 / A2 HVPS Assembly... CRU Guide Assembly Left (Power supplyfor magnet roll)

p. 319 p. 321

DTS Fig. 11, p. 375 / A3 HVPS Assembly... High Harness Assembly (Power supplyfor Detack Saw)

p. 319 p. 321

M1 Fig. 14, p. 378 / C1 Harness... Lift Up Motor p. 353 p. 357





M2 Fig. 14, p. 378 / C4 Flat Harness... Transport Motor p. 353 p. 357

P1 Fig. 14, p. 378 / A3 Flat Harness... Kit Feed Roller p. 353 p. 357

P2 Fig. 14, p. 378 / A3 Flat Harness... Kit Feed Roller p. 353 p. 357

S1 Fig. 14, p. 378 / C1 Harness... Near Empty Sensor p. 353 p. 357

S2 Fig. 14, p. 378 / C1 Harness... Lower Position Sensor p. 353 p. 357

S3 Fig. 14, p. 378 / C1 Harness... Size Sensor p. 353 p. 357

S6 Fig. 14, p. 378 / A4 Flat Harness... Tray Set Sensor 1 p. 353 p. 357

S7 Fig. 14, p. 378 / A4 Flat Harness... Tray Set Sensor 2 p. 353 p. 357

S8 Fig. 14, p. 378 / C4 Flat Harness... Sensor p. 353 p. 357

S9 Fig. 14, p. 378 / C4 Flat Harness... Left Hand Cover Open Switch p. 353 p. 357

S10 Fig. 14, p. 378 / A3 Flat Harness... Paper Level Sensor p. 353 p. 357

S11 Fig. 14, p. 378 / A3 Flat Harness... Upper Limit Sensor p. 353 p. 357

S12 Fig. 14, p. 378 / B3 Flat Harness... Right Hand Cover Open Switch p. 353 p. 357

TR Fig. 11, p. 375 / B3 HVPS Assembly... High Harness Assembly (Power supplyfor BTR)

p. 319 p. 321

XS1 Fig. 14, p. 378 / A2 LVPS... Harness p. 353 p. 357

XS2 Fig. 14, p. 378 / A2 LVPS... Flat Harness p. 353 p. 357

XS3 Fig. 14, p. 378 / A2 LVPS... Kit Connector p. 353 p. 353

XS4 Fig. 14, p. 378 / A1 Base Engine... Kit Connector p. 353 p. 353


1 2 3 4

1 2 3 4

A

B

C

A

B

C

HC2M111F

J421

J142, J942 J143, J943

J145J144

J207J135, J935

J222, J922J137, J937

J221J134

J132

Figure 10. Connectors, Printer


HC2M112F

J114J112

DB

CR

DTS

J151

TR

J123

J202

J201

J121

J203

J126J127

J122

J124J205J204,J904

J206J131

J31

J11

J17

J14

J18

J16

J23

J15

J19

J22

J13

J20

J12

J21

J182J190

J113

J180 J171

1 2 3 4

1 2 3 4

A

B

C

A

B

C

Figure 11. Connectors, Printer


hc2m126F

J201 J202J207

P207

J203J205

J204, J904

J206, J906

1 2 3 4

A

B

A

B

Figure 12. Connectors, Trays


hc2m117F

J184

J187

J183

J186J193

J196

J197J192

J195

J198P182

1 2 3 4

A

B

A

B

Figure 13. Connectors, Duplex


1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m128F

XS4

XS1XS3

XS2

S2M1

S1S3

S12

S11

P1S10

P2 S6S7

S9

S8

M2

Figure 14. Connectors, HCF


Printed Wiring Boards (PWBs)Table 62. Printed Wiring Boards (PWBs)

Unit PWB Figure /Reference

Parts CatalogAsm.– Index

WiringDiagram

(Grid)

PinoutDiagram

(Grid)Removal

Printer Control panel (console) Fig. 15, p. 381 / 1 1–18, p. 548 p. 334 p. 336 p. 418

Controller PWB Fig. 15, p. 381 / 2 13–6, p. 578 p. 337 p. 338 p. 537

HVPS Fig. 15, p. 381 / 3 12–11, p. 575 p. 319 p. 321 p. 532

Feeder PWB Fig. 15, p. 381 / 4 3–1, p. 553 p. 342 p. 342 p. 420

LVPS Fig. 15, p. 381 / 5 12–4, p. 575 p. 311 p. 311 p. 521

MCU PWB Fig. 15, p. 381 / 7 12–8/9, p. 575 p. 310 p. 310p. 526 orp. 529

Duplex Interface PWB Fig. 15, p. 381/ 6 12–6, p. 575 p. 349 p. 349 p. 524

Duplex Duplex PWB Fig. 17, p. 382 / 9 30–10, p. 652 p. 349 p. 349 p. 627

Feeder Tray 2/3 Feeder PWB Fig. 16, p. 381 / 8 20–11, p. 697 p. 342 p. 342 p. 674

HCF LVPS Fig. 18, p. 383 / 10 42–25, p. 778 p. 353 p. 357 p. 674


HC2M116F

1

2

3

4

56

7

Figure 15. Printed Wiring Boards (PWBs): Printer

8

HC2M125F

Figure 16. Printed Wiring Boards (PWBs): Trays


HC2M121F

9

Figure 17. Printed Wiring Boards (PWBs): Duplex


hc2m129F

10

Figure 18. Printed Wiring Boards (PWBs): HCF


SensorsTable 63. Sensors

Unit Sensor Figure /Reference


WiringDiagram

(Grid)

PinoutDiagram

(Grid)Removal

Printer

CRU sensor Fig. 19, p. 387 / 1 11–15, p. 572 p. 315 p. 317 p. 503

Full stack sensor Fig. 19, p. 387/ 2 8–7, p. 564 p. 313 p. 314 p. 487

Exit sensor Fig. 19, p. 387/ 3 8–25, p. 564 p. 313 p. 314 p. 487

Temperature sensor Fig. 19, p. 387/ 4 9–9, p. 567 p. 313 p. 314 p. 487

Registration sensor Fig. 19, p. 387/ 5 7–6, p. 562 p. 322 p. 324 p. 484

Auxiliary tray no-paper sensor Fig. 19, p. 387/ 6 5–9, p. 557 p. 322 p. 324 p. 460

Toner sensor Fig. 19, p. 387/ 7 5–13, p. 557 p. 331 p. 331 p. 462

Cassette no-paper sensor Fig. 19, p. 387/ 10 3–11, p. 553 p. 342 p. 342 p. 430

DuplexDuplex stack sensor Fig. 21, p. 388 / 14 30–17, p. 652 p. 349 p. 349 p. 635

Duplex pass sensor Fig. 21, p. 388/ 13 30–13, p. 652 p. 349 p. 349 p. 633

Feeder Tray 2/3 cassette no-paper sensor Fig. 20, p. 388 / 12 20–21, p. 697 p. 342 p. 342 p. 683


Table 63. Sensors (continued)

Unit Sensor Figure /Reference


WiringDiagram

(Grid)

PinoutDiagram

(Grid)Removal

HCF

Near empty sensor Fig. 22, p. 389 / 17 41–11, p. 776 p. 353 p. 353 p. 731

Size sensor Fig. 22, p. 389 / 18 41–15, p. 776 p. 353 p. 353 p. 735

Lower position sensor Fig. 22, p. 389 / 19 41–12, p. 776 p. 353 p. 353 p. 733

Sensor Fig. 22, p. 389 / 27 42–10, p. 778 p. 353 p. 353 p. 745

Upper limit sensor Fig. 22, p. 389 / 23 42–11, p. 778 p. 353 p. 353 p. 750

No paper sensor Fig. 22, p. 389 / 25 42–28, p. 778 p. 353 p. 353 p. 747

Tray set sensor 1 Fig. 22, p. 389 / 21 42–18, p. 778 p. 353 p. 353 p. 756

Tray set sensor 2 Fig. 22, p. 389 / 20 42–19, p. 778 p. 353 p. 353 p. 756

Paper level sensor Fig. 22, p. 389 / 22 42–12, p. 778 p. 353 p. 353 p. 752


SwitchesTable 64. Switches

Unit Switch Figure /Reference


WiringDiagram

(Grid)

PinoutDiagram

(Grid)Removal

PrinterInterlock switch Fig. 19, p. 387 / 8 12–1, p. 575 p. 311 p. 311 p. 513

Fuser cover switch Fig. 19, p. 387/ 9 12–2, p. 575 p. 332 p. 332 p. 516

DuplexDuplex cover switch 1 Fig. 21, p. 388 / 15 30–11, p. 652 p. 349 p. 349 p. 629

Duplex cover switch 2 Fig. 21, p. 388/ 16 30–12, p. 652 p. 349 p. 349 p. 631

Trays Paper size switch (on feederPWB)

Fig. 20, p. 388 / 11 20–11, p. 697 p. 342 p. 342 p. 674

HCFRight hand cover open switch Fig. 22, p. 389 / 24 42–9, p. 778 p. 353 p. 353 p. 743

Left hand cover open switch Fig. 22, p. 389 / 26 42–20, p. 778 p. 353 p. 353 p. 758


hc2m223F

7

1 2

34

5

6

8

9

10

Figure 19. Sensors and Switches: Printer


12

hc2m224F

11

Figure 20. Sensors and Switches: Trays

hc2m225F

13

14

15

16

Figure 21. Sensors and Switches: Duplex


17

hc2m127F

18 19

20212223

24

2526

27

Figure 22. Sensors and Switches: HCF


Mechanical and MiscellaneousTable 65. Mechanical and Miscellaneous Items

Unit Item Figure / Reference Parts Catalog Asm.– Index

Printer

Laser Unit (ROS) Fig. 24, p. 393 / 28 11–20, p. 572

Fuser Assembly Fig. 24, p. 393 / 29 8, p. 564

BTR Roll Fig. 24, p. 393 / 30 6–1, p. 559

EP Cartridge Fig. 24, p. 393 / 31 11–40, p. 572

Pick Up Roller Fig. 23, p. 392 / 1 6–8, p. 559

Metal Registration Roller Fig. 23, p. 392 / 2 7–10, p. 562

Rubber Registration Roller Fig. 23, p. 392 / 3 7–11, p. 562

Drum (part of EP Cartridge) Fig. 23, p. 392 / 4 11–40, p. 572

Heat Roller (part of Fuser Assembly) Fig. 23, p. 392 / 5 9–10, p. 567

Offset/Exit Roller Fig. 23, p. 392 / 6 31–9, p. 655

Pressure Roll (part of Fuser Assembly) Fig. 23, p. 392 / 12 9–15, p. 567

BTR Assembly Fig. 23, p. 392 / 13 6–1, p. 559

Rear Roll Assembly Fig. 23, p. 392 / 16 4–11, p. 555

Turn Roll Assembly Fig. 23, p. 392 / 17 4–10, p. 555


Table 65. Mechanical and Miscellaneous Items (continued)

Unit Item Figure / Reference Parts Catalog Asm.– Index

Duplex

Exit Pinch Roller Fig. 23, p. 392 / 7 30–5, p. 652

Offset Pinch Roller Fig. 23, p. 392 / 8 31–7, p. 652

Offset Roller Fig. 23, p. 392 / 9 31–8, p. 655

Duplex Upper Roller Fig. 23, p. 392 / 10 31–11, p. 655

Duplex Upper Pinch Roller Fig. 23, p. 392 / 11 30–5, p. 652

Duplex Lower Roller Fig. 23, p. 392 / 14 31–12, p. 655

Duplex Lower Pinch Roller Fig. 23, p. 392 / 15 30–6, p. 652

Trays

Tray 1 Pinch Roller Fig. 23, p. 392 / 18 4–11, p. 555

Tray 1 Turn Roller Assembly Fig. 23, p. 392 / 19 4–10, p. 555

Tray 1 Feed Roller Fig. 23, p. 392 / 20 4–1, p. 555

Tray 2 Pinch Roller Fig. 23, p. 392 / 21 20–1, p. 700

Tray 2 Turn Roller Assembly Fig. 23, p. 392 / 22 21–20, p. 700

Tray 2 Feed Roller Fig. 23, p. 392 / 23 21–11, p. 700

HCF

Pinch roll Fig. 23, p. 392 / 24 42–5, p. 778

Transport roll Fig. 23, p. 392 / 25 42–7, p. 778

Pinch roll Fig. 23, p. 392 / 26 42–5, p. 778

Feed roll Fig. 23, p. 392 / 27 42–14, p. 778


hc2m785F

FRONT

1

34

56

7 8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

2

Figure 23. Mechanical


hc2m226F

2829

30

31

Figure 24. Miscellaneous


Chapter 6. Removal Procedures, AdjustmentsFuser Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

Left Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403

Right Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405

Left Side Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407

Left Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409

Right Cover Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411

Front Side Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413

Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415

Pop Up Cover Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .417


Console Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .419

Feeder PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .420Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421

Turn In Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423

Turn Chute Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425

Cassette Guide Assembly Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .426Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428

Cassette No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .430Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .430Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431

Cassette Guide Assembly Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435

Cassette No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .436Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .437

Feed Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438You may follow either procedure A or B.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438Procedure A Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Procedure B Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440

Chapter 6. Removal Procedures, Adjustments 395

Feed Shaft Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .442Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .444

Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .446Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .448

Electromagnetic Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450

Turn Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452

Rear Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .454

Front Tray Assembly and Front in Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .456

Auxiliary Tray Bracket Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458

Auxiliary Tray No Paper Sensor/Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461

Toner Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463

Front Bottom Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .465


BTR Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .466Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467

Transport Chute Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471

Pick Up Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .475

Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478

Retard Pad Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482

Registration Sensor/Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486

Fuser Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .488

Main Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .489Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490

Paper Handling Gear Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494

Registration Clutch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496


Main Gear Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499

Pop Up Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .502

CRU Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .505

CRU Guide Assembly Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .506Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .507Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .508

CRU Guide Assembly Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .510Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .510Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511

Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .513Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .515

Fuser Cover Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .516Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .517

Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .518Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .519

LVPS Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .522Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .523

Duplex Interface PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525


MCU PWB without MCU Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527

MCU PWB with MCU Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .529Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531

HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .532Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533

Controller Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .536

Controller PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .538

Controller PWB SIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540

Network Interface Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542


Fuser Cover AssemblyAsm-Index: 1-1, page 548.

hc2m957f

FRONT1

64

2

5 3

Figure 25. Fuser Cover Assembly Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove duplex unit (See page 615), if supplied.

3. Open the fuser cap cover (1) (Asm-Index: 1-3, page 548).

4. Lift up the fuser cap cover and remove from the fuser cover (2) (Asm-Index: 1-2, page 548).

5. Open the fuser cover and hold the cover midway (approximately 30 degrees).6. Use you right hand to hold the left end of the fuser cover, and press its center from the inside. Use your

left hand to unhook the right side hinge pin (5) from the hinge hole on the rear tie plate (6) (Asm-Index:10-5, page 570).

7. Release the left side hinge pin (3) of the fuser cover from the hinge hole on the rear tie plate (6).

ReplacementReverse the Removal procedure.


Left Top CoverAsm-Index: 1-4, page 548.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover assembly (Asm-Index: 1-1, page 548).

12

2

hc2m958F

J131

Figure 26. Left Top Cover Removal


3. Open the front tray assembly (Asm-Index: 5-1, page 557).

4. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572).

5. Remove the two screws (2) securing the left top cover to the printer frame.6. Lift up the back of the left top cover.7. Release the hook (3) from the front side cover (Asm-Index: 1-11, page 548) and remove the left top cover

from the printer body.

Attention: Support the left top cover to prevent damage to the console earth wire and the console harness.

8. Turn the left top cover to the left.9. Disconnect CN1 of the console harness (Asm-Index: 13-8, page 578) at the back of the console assembly




Right Top CoverAsm-Index: 1-5, page 548.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the fuser cover assembly (See page 400).

2

2

hc2m413f

1

Figure 27. Right Top Cover Removal


3. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572)

4. Remove the two screws (2) securing the right top cover.5. Lift the cover away from the printer frame.



Left Side Cover AssemblyAsm-Index: 1-6, page 548.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Loosen the two knurled screws (1) securing the left cover assembly (2).

1

6

FRONT

hc2m972f

17

7

6

8

8

3

5

2

4

Figure 28. Left Side Cover Removal


3. Slide the cover backwards to remove its front edge from the front side cover (3) (Asm-Index: 1-11, page548), and remove the cover from the printer frame.

Replacement1. Insert the top edge of the cover (4) into the top slot (5).2. Line the three hooks (6) up with the three openings (7) in the printer frame.3. Slide the cover toward the front of the printer until the front tabs (8) fit into the grooves on the front side

cover (3).

Attention: Ensure that the top edge of the cover fits inside the lower edge of the left top cover.4. Secure the left cover assembly using two knurled screws.


Left Lower CoverAsm-Index: 1-9, page 548.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left cover assembly (See page 406).

3. Remove the two screws (1) securing the left lower cover (2).4. Remove the cover from the printer frame.

1

1

2

hc2m415f

Figure 29. Left Lower Cover Removal


Right Cover AssemblyAsm-Index: 1-10, page 548.


1hc2m416f

3

3

3

2

Figure 30. Right Cover Assembly Removal


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.



Front Side CoverAsm-Index: 1-11, page 548.

2 hc2m417f

1

1

Figure 31. Front Side Cover Removal



3. Remove the left top cover (See page 402).

4. Remove the left cover assembly (See page 406).

5. Push down on the two hooks (1) at the upper end of the front side cover and move the top of the coveraway from the printer frame.

6. Lift up the cover slightly to clear the two hooks (2) at the bottom of the cover and remove the cover fromthe printer frame.

Replacement1. Hold the front side cover slightly tilting the upper side toward the front, and insert the hooks (2) on the

bottom end of the cover into the opening in the printer frame.2. Push down on the two hooks (1) at the upper end of the cover and insert them into the openings of the

printer frame.3. Replace the left cover assembly (See page 406).

4. Replace the left top cover (See page 402).

5. Close the fuser cover assembly (Asm-Index: 1-1, page 548).


Exit CoverAsm-Index: 1-12, page 548.


Note: Removing the fuser allows cables/wires to be re-routed on the cover wire retainer during replacement.



5. Close the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572).

1 12

3

hc2m418f

Figure 32. Exit Cover Removal


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

touch the cover.

8. Lift the cover and remove it from the printer frame.

Replacement1. Lift the full stack actuator and hold it out of the way so that it will not touch the exit cover during step 2.2. Place the cover onto the printer frame.3. Secure the cover using two screws (silver, collared, 10mm).4. Open the Pop up/ROS assembly.5. Replace the right top cover (See page 404).


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


Pop Up Cover AssemblyAsm-Index: 1-13, page 548.

RemovalSee Figure 33.

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

12

2

3

3

hc2m419f

Figure 33. Pop Up Cover Assembly Removal




5. Remove the exit cover (See page 414).

6. Open the Pop up/ROS assembly (1) (Asm-Index: 11-1∼11-23, page 572).

7. Remove the two screws (2) securing the pop up cover assembly.8. Close the Pop up/ROS assembly.9. Slide the pop up cover assembly slightly toward the front of the printer to disengage the hooks (3) at the

front and back of the cover.10. Lift the cover assembly and remove the cover from the pop up frame (Asm-Index: 11-1, page 572).



Console AssemblyAsm-Index: 1-18, page 548.

JCN1

CN1

J131

2

1

hc2m41af

Figure 34. Console Assembly Removal



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.



Feeder PWBAsm-Index: 3-1, page 553.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550).


4. Remove the left side cover assembly (See page 406).

2

4

1

3

3

FRONT

J203

J202J201

hc2m973f

Figure 35. Feeder PWB Removal


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.



Turn In ChuteAsm-Index: 3-4, page 553.

4

2

3

FRONT

hc2m974F

1

Figure 36. Turn In Chute Removal



3. Hold open the turn chute assembly (Asm-Index: 3-5, page 553).

4. Flex the left side arm (1) of the turn in chute and remove its hinge hole from the pin (2) on the cassetteguide assembly left (Asm-Index: 3-6, page 553).

5. Remove the turn in chute (3) from the cassette guide (4).



Turn Chute AssemblyAsm-Index: 3-5, page 553.

hc2m433F

2

21

Figure 37. Turn Chute Assembly Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the turn in chute (See page 422).

3. Hold the turn chute assembly (1) half open.4. Unhook the stoppers from the cassette guide left and right.5. Hold the chute assembly open and slide it to the left.6. Lift the rear of the printer and pull down the right side of the chute.7. Slide the chute to the right and remove it from the printer.8. Lower the printer.



Cassette Guide Assembly LeftAsm-Index: 3-6, page 553.


J206 J204

J203

hc2m434f

3 3

5

4

1

Figure 38. Cassette Guide Assembly Left Removal





6. Remove the turn in chute (See page 422).

7. Remove the turn chute assembly (See page 424).

8. Remove the controller assembly (See page 535).

9. Remove the LVPS assembly (See page 521).

10. Disconnectv J203 of the feeder harness (Asm-Index: 3-12, page 553) from the feeder PWB (Asm-Index: 3-1, page

553),

v J204 from the feed solenoid (Asm-Index: 4-8, page 555), and

v J206 of the feeder harness from the electromagnetic clutch (Asm-Index: 4-9, page 555).

11. Release the electromagnetic clutch side of the feeder harness from the clamp.12. Remove the four screws (1) securing the cassette guide assembly left from outside of the frame.

13. Using a flat blade screwdriver, push the three hooks (3) at the bottom of the cassette guide, up and in,one by one, to release them from the printer frame.

14. Tilt the cassette guide (4), pulling its bottom edge from the inside of the printer frame (5).15. Ensure that the three upper hooks of the cassette guide are released from the printer frame.


16. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator(Asm-Index: 3-16, page 553).

17. Push all harnesses on the cassette guide to free them from the printer frame.18. Remove the cassette guide from the printer frame.

Replacement1. Hold the cassette guide assembly left with the bottom to the right and the top to the left so that it will not

interfere with the cassette no paper actuator.2. Insert the cassette guide into the paper cassette well.3. Insert all connectors on the cassette guide through their openings in the printer frame.4. Place the upper three hooks of the cassette guide in their holes in the printer frame.5. Pull the harnesses to keep them from being pinched between the cassette guide and the printer frame.

Note: Adjust the position of cassette guide by sliding it to the front or rear so that the positioning pins onthe cassette guide enter into the openings in the printer frame.

6. Press on the bottom of the cassette guide to tilt it up until the upper and lower hooks lock into position.7. Secure the cassette guide from the outside of the printer frame using the four screws (1).8. Reconnect:v J203 to the feeder PWB,v J204 to the feed solenoid, andv J206 to the electromagnetic clutch.

9. Insert the electromagnetic clutch harness into the harness clamp.10. Replace the LVPS assembly (See page 521).

11. Replace the controller assembly (See page 535).

12. Replace the turn chute assembly (See page 424).

13. Replace the turn in chute (See page 422).


14. Replace the front side cover (See page 412).

15. Replace the left cover assembly (See page 406).




Cassette No Paper SensorAsm-Index: 3-11, page 553.


3. Open the fuser cover assembly (See page 400).


1J205

hc2m435f

2

3

Figure 39. Cassette No Paper Sensor Removal






9. Swing the arm of the cassette no paper actuator (1) (Asm-Index: 3-16, page 553) to the rear direction sothat the actuator is away from the cassette no paper sensor (2).

10. Open the turn chute assembly (Asm-Index: 3-5, page 553).

11. Using a small screwdriver, release the hooks (3) of the cassette no paper sensor from the cassette guideassembly left (Asm-Index: 11-30, page 572).

Attention: Do not move the cassette no paper sensor away. It is connected with the feeder harness.

12. Disconnect J205 from the sensor.13. Remove the sensor.

Replacement1. Swing up the arm of the cassette no paper actuator to the rear so that the actuator is away from the

cassette no paper sensor.2. Reconnect J205 to the cassette no paper sensor.3. Position the sensor in the opening of the cassette guide, and press the sensor into place until it snaps

into position.4. Put the extra length of the harness into the wiring channel of the cassette guide so that the harness does

not interfere with the gears.5. Replace the turn in chute (See page 422) and close the turn chute assembly.







11. Replace the paper cassette.


Cassette Guide Assembly RightAsm-Index: 3-13, page 553.



4. Remove the right cover assembly (See page 410).

hc2m436f

2 4

1

13

3

Figure 40. Cassette Guide Assembly Right Removal


5. Remove the front tray assembly (See page 455).



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.


Replacement1. Hold the cassette guide assembly right with the lower side to the left and the upper side to the right.2. Insert the cassette guide into the paper cassette well.3. Position the upper three hooks of the cassette guide in their respective holes.

Note: Adjust the position of the cassette guide by sliding it to the front or rear so that the positioning pinson the cassette guide enter into the openings in the printer frame.

4. Press the lower side of the cassette guide tilting it up until the upper and lower hooks are in position andthe lower hooks snap into place.

5. Secure the cassette guide using three screws (gold, self tapping, 8mm).6. Replace the turn chute assembly (See page 424).


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).



Cassette No Paper ActuatorAsm-Index: 3-16, page 553.





2

hc2m437f

1

Figure 41. Cassette No Paper Actuator Removal



7. Remove the front tray assembly (See page 455).




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.



Feed RollAsm-Index: 4-1, page 555.

You may follow either procedure A or B.Note: The feed rollers are in the correct position for removal if power is switched off approximately 4 seconds

after initiating a print command.

hc2m441f

5

3

1

4

2

Figure 42. Feeder Roll Removal


Procedure A Removal1. Install the paper cassette (Asm: 2, page 550) (with paper).

2. Open the turn chute assembly (Asm-Index: 3-5, page 553) and watch the paper path.

3. Run a test print and switch off the main switch when the front end of the paper touches the turn rollassembly (Asm-Index: 4-10, page 555).

4. Remove the paper cassette.5. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paper

actuator (Asm-Index: 3-16, page 553) with your first, second and third fingers.

6. Press on the hook of the feed roll (1) to the front using your thumb to remove it.

Replacement1. Align the locating pin of the feed roll with the hole in the feed shaft.2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly.

Note: Ensure that the cams are located between the left and right pairs of the feed roll.3. Switch on the main power.4. Replace the paper cassette.

Procedure B Removal1. Remove the fuser cover assembly (See page 400).








8. Press down on the armature of the feed solenoid (2) (Asm-Index: 4-8, page 555) to engage the feed gear(3) (Asm-Index: 4-5, page 555) with the feed idler gear (4) (Asm-Index: 4-15, page 555).

9. Rotate the rotor (5) of the main motor (Asm-Index: 10-6, page 570) clockwise until the rubber surface ofthe feed roll faces to the front.

Attention: Do not damage the cassette no paper actuator (Asm-Index: 3-16, page 553) and the rubber rolls.

10. Hold the shaft of the feed shaft assembly (Asm-Index: 4-2, page 555) away from the cassette no paperactuator, with your first, second and third fingers.

11. Press on the hook of the feed roll to the front using your thumb to remove it.

ReplacementAttention: Do not damage the cassette no paper actuator and the rubber rolls.

1. Align the locating pin of the feed roll with the hole in the feed shaft.2. Press the feed roll to the front to install it onto the shaft of the feed shaft assembly.

Note: Ensure that the cams are located between the left and right pairs of the feed roll.3. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of

the feed roll (Asm-Index: 4-1, page 555) up until the feed gear (Asm-Index: 4-5, page 555) is releasedfrom the feed idler gear (Asm-Index: 4-15, page 555).






Feed Shaft AssemblyAsm-Index: 4-2, page 555.



hc2m442f

3

8

1

4

2

5

67

Figure 43. Feeder Shaft Assembly Removal









11. Remove the four feed rolls (See page 438).

12. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page555) and the feed solenoid (3) (Asm-Index: 4-8, page 555).

13. Remove the E-ring (4) that secures the feed gear to the feed shaft assembly (5).14. Hold down the armature of the feed solenoid and remove the feed gear together with the feed core

(Asm-Index: 4-3, page 555) and the feed core spring (Asm-Index: 4-4, page 555).

15. Remove the E-ring (6) that secures the right end the feed shaft assembly and remove the right side feedbearing (7) (Asm-Index: 4-6, page 555).

16. Slide the feed shaft to the left and remove the E-ring (8) that secures its left end.


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.


ReplacementAttention: Do not damage the cassette no paper actuator and the rubber rolls.

1. Position the cassette no paper actuator in the lower position.2. Hold the feed shaft assembly with the flat side to the left.3. Hold the feed shaft, left end lowered and insert its right end into the right opening in the printer frame.4. Slide the feed shaft to the right and insert its left end to the feed bearing.5. Slide the feed shaft to the left and install an E-ring in the second groove from the left end. You may pull

out the right end of the shaft to ease the installation of the E-ring.6. Pressing the left end of the feed shaft to the right, insert the right side feed bearing into its opening in the

printer frame.7. Reinstall an E-ring to secure the right end of the feed shaft.8. Rotate the shaft and position the flat side up.9. Holding down the armature of the feed solenoid, install the feed gear together with the feed core and the

feed core spring.10. Secure the feed gear to the feed shaft using an E-ring.11. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) to the position that the larger holes on

the feed shaft can be seen from the back of the printer body.

12. Replace the four feed rolls (See page 438).

13. Reinstall the feed spring between the feed gear and the feed solenoid.14. Rotate the rotor of the main motor clockwise to place the rubber surface of the feed roll up until the feed

gear is released from the feed idler gear (Asm-Index: 4-15, page 555).





Feed SolenoidAsm-Index: 4-8, page 555.


J204

hc2m443f

3

4

2

5

1

Figure 44. Feed Solenoid Removal






7. Remove the feed spring (1) (Asm-Index: 4-7, page 555) from the feed gear (2) (Asm-Index: 4-5, page 555)and the feed solenoid (3).

8. Disconnect J204 of the feed solenoid (4) from the feeder harness (Asm-Index: 3-12, page 553) on thecassette guide assembly left (Asm-Index: 3-6, page 553).

9. Remove the screw (5) securing the feed solenoid to the cassette guide and remove the solenoid.


Replacement1. Place the feed solenoid in position and secure it using a screw (silver, 6mm).2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly left.

Attention: Route the harness so that it does not touch the gears.3. Reinstall the feed spring between the feed gear and the feed solenoid.4. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise to place the rubber surface of

the feed roll (Asm-Index: 4-1, page 555) up until the feed gear is released from the feed idler gear(Asm-Index: 4-15, page 555).

5. Press the armature of the feed solenoid and ensure the feed gear is released from the armature.6. Turn the feed gear clockwise and ensure the armature of the feed solenoid holds the feed gear.7. Replace the controller assembly (See page 535).






Electromagnetic ClutchAsm-Index: 4-9, page 555.






J206hc2m444f

1

2

Figure 45. Electromagnetic Clutch Removal


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

Replacement1. Place the electromagnetic clutch on the turn roll assembly and insert the notch on the clutch to the arm

over the printer frame.2. Secure the clutch using an E-ring.3. Reconnect P/J206 to the clutch.

Attention: Route the harness so that it does not touch the gears.4. Replace the controller assembly (See page 535).




8. Remove the fuser cover assembly (See page 400).


Turn Roll AssemblyAsm-Index: 4-10, page 555.






hc2m445f

12

4

3

5

Figure 46. Turn In Roll Assembly Removal






11. Remove the electromagnetic clutch (See page 449).

12. Remove the left side E-ring (1) securing the turn gear (2) (Asm-Index: 4-12, page 555) and remove thegear from the turn roll assembly (3).

13. Remove the bearing from the turn roll assembly.14. Remove the right side E-ring (5) securing the right side turn bearing (6) and remove the bearing from the

turn roll assembly.15. Slide the turn roll assembly to the left, and remove its right end from the printer frame.16. Slide the right end of the turn roll assembly backward, and remove its left end from the printer frame.



Rear Roll AssemblyAsm-Index: 4-11, page 555.






5

1 2

hc2m446f

63

4

Figure 47. Rear Roll Assembly Removal






11. Remove the E-ring (1) securing the right side turn bearing (2) (Asm-Index: 4-13, page 555) and removethe bearing from the printer frame.

12. Remove the E-ring (3) securing the turn gear (4) (Asm-Index: 4-12, page 555) and remove the gear fromthe rear roll assembly (5).

13. Remove the left side turn bearing (6) from the rear roll assembly.14. Slide the rear roll assembly to the left, and remove its right end from the printer frame.15. Slide the right end of the rear roll assembly to the rear, and remove its left end from the printer frame.



Front Tray Assembly and Front in TrayAsm-Index: 5-1 and 5-4, page 557.





hc2m451f

1

2

3 1

Figure 48. Front Tray Assembly and Front In Tray Removal




8. Remove the two screws (1) securing the front in tray (2).9. Open the front tray and pull out the front in tray together with the front tray assembly (3).

10. Flex the arm of the front in tray to release the hinge on the front tray assembly to separate the front intray and the front tray assembly.



Auxiliary Tray Bracket AssemblyAsm-Index: 5-7, page 557.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the front tray assembly (Asm-Index: 5-1, page 557).

J137J222

hc2m452f

1

2

3

1

4

Figure 49. Auxiliary Tray Bracket Assembly Removal


3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and keep it open during theoperation below.

4. Remove the EP cartridge (Asm-Index: 11-40, page 572).

5. Remove the two screws (1) securing the auxiliary tray bracket assembly (2) to the printer frame.6. Press down the front bottom tray (3) (Asm-Index: 5-5, page 557).

7. Slide the auxiliary tray bracket assembly slightly to the front to release the hooks on the printer framefrom the opening in the auxiliary tray bracket assembly.

8. Raise the right end of the auxiliary tray bracket and slide it slightly to the right.9. Release the left end of the auxiliary tray bracket from the printer frame without pulling the harnesses (4)

connected at the left rear of the auxiliary tray bracket.10. Disconnect J137 of the high harness assembly (Asm-Index: 6-5, page 559) and J222 of the toner relay

harness (Asm-Index: 12-18, page 575) from the auxiliary tray bracket.

11. Tilt the auxiliary tray bracket rear side up and remove it from the printer frame.

Replacement1. Open the front tray cover.2. Open the Pop up/ROS assembly and keep it open during the following steps.3. Press down the front bottom tray.4. Hold the auxiliary tray bracket assembly in one hand and hold the arm of the auxiliary tray no paper

actuator (Asm-Index: 5-10, page 557) in the up position using the other hand.

5. Tilt the auxiliary tray bracket rear side up and place the left end of the bracket slightly front from the finalposition holding the right end up.

6. Reconnect J137 and J222 and place the harnesses outside of the paper well area.

Note: You may need to remove the MCU PWB (See page 526 or 529) to reconnect J137 and J222. Afterreconnection, replace the MCU PWB.


7. Hold the arm of the auxiliary tray no paper actuator up and place the auxiliary tray bracket in the printerframe.

Note: Ensure that the auxiliary tray no paper actuator fits into the hole in the front bottom tray.8. Secure the bracket to the printer frame using two screws (silver, 6mm).9. Replace the EP cartridge.

10. Close the Pop up/ROS assembly.11. Close the front tray assembly.


Auxiliary Tray No Paper Sensor/ActuatorAsm-Index: 5-9 and 5-10, page 557.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the auxiliary tray bracket assembly (See page 457).

3. Remove the screw (1) securing the auxiliary tray actuator holder (2) to the auxiliary tray bracket assembly(Asm-Index: 5-7, page 557).

J134

hc2m453f1

2

4

35

Figure 50. Auxiliary Tray No Paper Sensor/Actuator Removal


4. Remove the actuator holder from the bracket with the no paper sensor (3) and the auxiliary tray no paperactuator (Asm-Index: 5-10, page 557) by lifting the right (sensor) end of the holder to disengage the hook(4) from the auxiliary tray bracket.

5. Disconnect J134 of the auxiliary tray no paper harness (Asm-Index: 5-12, page 557) from the auxiliary trayno paper sensor and remove the harness from the clamp on the auxiliary tray actuator holder (Asm-Index:5-11, page 557).

6. Holding the arm of the no paper actuator (5) up, squeeze the hooks of the no paper sensor, and removethe sensor from the holder.

7. Push the actuator end (as opposed to the sensor flag end) of the actuator (5) rearwards until it snaps outof the holder.



Toner Sensor AssemblyAsm-Index: 5-13, page 557.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the EP cartridge (Asm-Index: 11-40, page 572).

J221

hc2m975f

1

2

3

Figure 51. Toner Sensor Assembly Removal


3. To remove the entire assembly:a. Snap out the toner sensor holder (Asm-Index: 5-15, page 557).

b. Disconnect P/J922 at the left side of the printer.4. To remove just the toner sensor:

a. Using a small flat blade screwdriver, expand the hooks (1) on the upper side of the toner sensor holder(2) (Asm-Index: 5-15, page 557) to remove the toner sensor (3) (Asm-Index: 5-14, page 557) from theholder.

b. Disconnect J221 of the toner sensor harness (Asm-Index: 5-17, page 557) from the sensor.



Front Bottom TrayAsm-Index: 5-5, page 557.


hc2m456f

1

1

2

3

Figure 52. Front Bottom Tray Removal








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.


14. Remove the CRU guide assembly left (See page 506).

15. Remove the CRU guide assembly right (See page 510).

16. Lift the left side of the front bottom tray (1) and pull the tray out from under the cams (2) on the ends ofthe pick up roll assembly (Asm-Index: 6-8, page 559).

17. Lift the left front side of the tray and slide it to the left to remove.18. Remove the tray.19. Remove the auxiliary tray normal force springs (3) (Asm-Index: 5-6, page 557) if necessary.



BTR AssemblyAsm-Index: 6-1, page 559.

hc2m461f

Figure 53. BTR Assembly Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the front tray assembly (Asm-Index: 5-1, page 557).

3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572). Ensure that it does not close duringthe operations below.

Attention: Do not touch the surface of the roll of the BTR assembly, the detack saw of the transport chuteassembly (Asm-Index: 6-2, page 559), or the window of the ROS assembly (Asm-Index: 11-20, page 572).

4. Turn up the levers of the BTR assembly (1) at both ends.5. Holding the levers, lift the BTR upwards at a 45 degree angle.6. Remove the BTR from the transport chute assembly.7. Place the BTR on a secure surface and cover the BTR with paper so as not to contaminate or damage it.



Transport Chute AssemblyAsm-Index: 6-2, page 559.



DTS

TR

J121

J13J124

J131P/J135

J14

hc2m462f

1

1

2

1

1

Figure 54. Transport Chute Assembly Removal (1)








10. Remove the front in tray together with the front tray assembly (See page 455).

11. Remove the fuser assembly (See page 487).


13. Remove the Pop up/ROS assembly (See page 500).


15. Carefully remove the BTR assembly (See page 466).

16. Disconnect J180 of the fuser cover harness from the duplex interface PWB (Asm-Index: 12-6, page 575).

17. Remove the duplex interface PWB (See page 524).

18. Disconnect:a. J13 and J14 of the high harness assembly (Asm-Index: 6-5, page 559) from the MCU PWB.

b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector ofthe high harness assembly to the LVPS assembly (Asm-Index: 12-4, page 575) and to the interlockswitch (Asm-Index: 12-1, page 575).

c. J TR and J DTS of the high harness from the HVPS (Asm-Index: 12-11, page 575).

d. J131 from the registration clutch assembly (Asm-Index: 10-9, page 570).

e. J135 from the pick up solenoid (Asm-Index: 6-17, page 559).


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.


Replacement1. Place the transport chute assembly on the printer frame.

Attention: Ensure the front bottom tray (Asm-Index: 5-5, page 557) is located under the pick up roll assembly(Asm-Index: 6-8, page 559) and the pick up cams (Asm-Index: 6-12, page 559) presses down the front bottomtray.

2. Secure the transport chute assembly to the printer frame using six screws (silver, collared, 10mm).

hc2m463f

334

DTS

DTS

TR

TRJ14J14

J13

J13

J124

J124

Figure 55. Transport Chute Assembly Removal (2)


3. Place the harnesses and wires to the side of the controller assembly (Asm-Index: 13-1, page 578).

4. Route all of the harnesses and wires connected to the high harness assembly (Asm-Index: 6-5, page559) under the clamps.

Attention: Route the harnesses so that they do not touch the gears.

5. Place the rear tie plate on the printer body and secure the tie plate using six screws (silver, 6mm) andtwo screws (gold, self tapping, 8mm).

6. Replace the MCU PWB together with the MCU holder (See page 529).

7. Reconnect:a. J13 and J14 of the high harness assembly to the MCU PWB.b. J124 of the high harness assembly connecting wires (black and white) from the drawer connector of

the high harness assembly to the LVPS assembly and to the interlock switch.c. J TR and J DTS of the high harness to the HVPS.d. J131 to the registration clutch assembly.e. J135 to the pick up solenoid.

8. Replace the duplex interface PWB (See page 524).

9. Reconnect P/J180 of the fuser cover harness to the duplex interface PWB.10. Replace the BTR assembly (See page 466).

11. Replace the auxiliary tray bracket assembly (See page 457).

12. Replace the Pop up/ROS assembly (See page 500).


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).


Pick Up RollAsm-Index: 6-9, page 559.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the auxiliary tray cover (Asm-Index: 5-2, page 557).

3. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and ensure it does not close duringthe operations below.

hc2m465f

1

2

1

Figure 56. Pick Up Roll Removal


4. Remove the EP cartridge (Asm-Index: 11-40, page 572).

5. Moe the auxiliary tray bracket assembly away from the rolls457), only diconnect the connectors ifnecessary.

6. If the rolls are not oriented as shown, you may need to rotate the shaft with the following procedure:a. Remove the controller assembly (See page 535).

b. Press on the armature of the pick up solenoid (Asm-Index: 6-17, page 559) down to engage the pickup gear (Asm-Index: 6-15, page 559) with the drive.

c. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up cams(Asm-Index: 6-12, page 559) are face down.

Note: Repeat steps 5 hrough 7 for right and left side rolls.

7. Release the hook on the core roll (1) (Asm-Index: 6-10, page 559) from the groove on the pick up shaft,using a flat blade screwdriver or finger nail. Slide the core roll away from the pick up roll (2).

8. Slide the pick up roll in the same direction as step 7 until it is clear of the drive pin on the pick up shaft.9. Remove the pick up roll from the shaft.

ReplacementNote: Repeat steps 1 through 3 for right and left side rolls.1. Holding the rubber side of the pick up roll up, place it on the pick up shaft on the outside of the drive pins

on the pick up shaft.

Attention: The arrows molded into the side of the pick up rolls show the direction of rotation. Be sure toinstall the rolls correctly.2. Slide the pick up roll inside inserting the drive pins on the pick up shaft into the grooves on the roll.3. Pressing down slightly on the retard pad assembly, (Asm-Index: 6-18, page 559), slide the core roll on the

same direction as step 2, until its hook snaps into the groove on the pick up shaft.



5. Replace the EP cartridge.6. Close the Pop up/ROS assembly.


Pick Up SolenoidAsm-Index: 6-17, page 559.



P/J135hc2m466f

1

2

3

4

5 2

Figure 57. Pick Up Solenoid Removal





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).


9. Remove the MCU PWB (See page 526) together with the MCU holder (Asm-Index: 12-9, page 575).


11. Press the armature (1) of the pick up solenoid (2) down.12. Rotate the rotor of the main motor (Asm-Index: 10-6, page 570) clockwise until the pick up gear (3)

(Asm-Index: 6-15, page 559) stops.

13. Press down again on the armature of the pick up solenoid.14. Remove the pick up spring (4) (Asm-Index: 6-16, page 559) from the pick up gear and the housing of the

transport chute assembly (Asm-Index: 6-2, page 559).

15. Disconnect P/J135 from the harness for the pick up solenoid.16. Remove the screw (5) securing the solenoid on the transport chute through the opening in the left frame

assembly (Asm-Index: 10-11, page 570).

17. Remove the solenoid from the transport chute through the opening in the left frame.

Replacement1. Place the pick up solenoid in position on the transport chute assembly through the opening in the left

frame assembly so that the armature of the pick up solenoid meshes with the pick up gear.2. Secure the solenoid on the transport chute assembly through the opening in the left frame, using a screw

(gold, self tapping, 8mm).


3. Reconnect P/J135 to the harness for the pick up solenoid and route the harness so that it does notinterfere with the gears.

4. Replace the pick up spring between the pick up gear and the housing of the transport chute assembly.5. Press the armature of the pick up solenoid down.6. Rotate the rotor of the main motor clockwise until the pick up gear stops (the rubber side of the pick up

rolls are face up).7. Replace the auxiliary tray bracket assembly (See page 457).

8. Replace the MCU PWB (See page 526) together with the MCU holder.

9. Replace the duplex interface PWB (See page 524).

10. Reconnect J180 to the duplex interface PWB11. Replace the controller assembly (See page 535).






Retard Pad AssemblyAsm-Index: 6-18, page 559.

1

2 1hc2m467f

Figure 58. Retard Pad Assembly Removal (1)





5. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and keep it open during theoperation below.


7. Remove the two pick up rolls (See page 474).

Apply the grease

3

4

5

5hc2m468f

Figure 59. Retard Pad Assembly Removal (2)


8. Remove the three screws (1) securing the transport front chute (2) (Asm-Index: 6-7, page 559).

9. Release the hook on the center core roll (3) (Asm-Index: 6-10, page 559) and slide the center core roll tothe right away from the retard pad assembly (4).

Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft(Asm-Index: 6-13, page 559).

10. Press the retard pad assembly to the front and pull its rear side up to release the hooks on its rear sidefrom the transport chute assembly.

11. Hold the retard pad assembly at a right angle and ensure two retard springs (5) (Asm-Index: 6-19, page559) hang on it.

12. Remove the retard pad assembly together with the two retard springs by pressing to the front.13. Remove the retard springs from the retard pad assembly.

Replacement1. Open the Pop up/ROS assembly and keep it open during the operation below.

Note: Step 2 is applicable only when installing a new retard pad assembly.2. Using a small flat blade screwdriver apply the grease, packed with the retard pad assembly package, to

the bearing groove on the transport chute assembly.3. Reinstall the retard springs on the retard pad assembly.4. Hold the surface of the retard pad assembly at a right angle and place it in the hollow of the transport

chute assembly together with two retard springs.5. Position the retard springs in the groove in the hollow of the transport chute assembly using a small flat

blade screwdriver.6. Press the retard pad assembly to the front tilting its rear side to insert its rear side into the hollow on the

transport chute assembly until the retard pad assembly snaps in place.


7. Slide the center core roll to the left until the hook on the core roll snaps in the groove on the pick upshaft.

Note: There are notches in the core roll to allow it to pass over the drive pins on the pick up shaft.8. Place the right side of the transport front chute on the transport chute aligning the position hole in the

front chute to the pin on the transport chute together with the grounding plate.9. Secure the transport front chute using three screws (silver, self tapping, with washer, 8mm).

10. Replace the two pick up rolls (See page 474).


12. Close the Pop up/ROS assembly.13. Replace the right cover assembly (See page 410).




Registration Sensor/ActuatorAsm-Index: 7-7, page 562.


7

8

31

1

526

5

4 P/J132

hc2m472f

10

9

Figure 60. Registration Sensor/Actuator Removal









10. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it to keep it open withoutthe force of the pop up springs in the next step.

11. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers.

12. Close the Pop up/ROS assembly.13. Remove the controller assembly (See page 535).

14. Disconnect P/J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interfacePWB (Asm-Index: 12-6, page 575).


16. Remove screws below:a. Two screws (1) securing the lower part of the back of the rear tie plate (2) to the base frame

assembly (Asm-Index: 10-2, page 570),

b. Two screws (3) securing the left of the tie plate to the left frame assembly (Asm-Index: 10-11, page570),

c. Two screws (4) securing the right of the tie plate to the right frame assembly (Asm-Index: 10-4, page570), and

d. Two screws (5) securing the upper part of the back of the tie plate to the transport chute assembly(Asm-Index: 6-2, page 559).


17. Disconnect P/J132 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration sensor(Asm-Index: 7-6, page 562).

18. Remove the screw (6) securing the registration sensor bracket (7) (Asm-Index: 7-9, page 562) to thetransport chute assembly.

19. Remove the registration sensor bracket from the transport chute.20. Press down the arm of the registration actuator and squeeze the two hooks securing the sensor (8) to

the bracket to remove the registration sensor.21. Turn the registration actuator (9) to match the cutout on its left side shaft with the opening in the frame of

the registration sensor bracket.22. Release the left side shaft of the registration actuator from the bracket.23. Slide the actuator to the left and remove it from the bracket together with the registration spring (10).



Fuser AssemblyAsm-Index: 8-1, page 564.

hc2m481f

4

5

3

2

1

Figure 61. Fuser Assembly Removal


Removal

CAUTION:

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

sf02

25

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

3. Loosen the two captured thumb screws (2) securing the fuser assembly (3) to the left frame assembly(Asm-Index: 10-11, page 570).

4. Lift up the fuser assembly (left end first), removing the locking tab (4) from the locking bracket (5).Removing the fuser assembly disconnects J142.

Replacement1. Place the fuser assembly on the top of the printer body, making sure J142 connects properly.2. Hold the tip of the full stack actuator (Asm-Index: 8-8, page 564) so that it does not interfere with the exit

cover (Asm-Index: 1-12, page 548).

3. Secure the fuser assembly to the left assembly using the two captured thumb screws.4. Close the fuser cover assembly.


Main MotorAsm-Index: 10-6, page 570.

hc2m4a1f

1

2

2

J16

Figure 62. Main motor Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the left top cover (See page 402).






8. Disconnect J16 of the main motor (1) from the MCU PWB (Asm-Index: 12-8, page 575).

Attention: Move the main motor to keep from touching the MCU holder (Asm-Index: 12-9, page 575) duringsteps 9 and 10.

9. Remove the three screws (2) securing the main motor to the left frame assembly (Asm-Index: 10-11,page 570).

10. Remove the main motor from the left frame assembly.

ReplacementAttention: Move the main motor to keep from touching the MCU holder during the following step.

1. Place the main motor in the left frame assembly and secure the motor using three screws (silver, 6mm).2. Rotate the rotor of the main motor clockwise manually, and ensure it rotates smoothly.3. Reconnect J16 of the main motor to the MCU PWB.4. Replace the duplex interface PWB (See page 524).

5. Reconnect J180 of the fuser cover harness to the duplex interface PWB.


Paper Handling Gear AssemblyAsm-Index: 10-7, page 570.

J131

hc2m4a2f

2

3

2

2

1

Figure 63. Paper Handling Gear Assembly Removal










10. Disconnect J131 of the high harness assembly (Asm-Index: 6-5, page 559) from the registration clutchassembly (Asm-Index: 10-9, page 570).

11. Unhook all the wires and harnesses from the clamp on the paper handling gear assembly (1).12. Remove the three screws (2) securing the paper handling gear assembly.13. Slightly pull out the gear assembly and release the registration clutch assembly from the drive bearing left

(3) (Asm-Index: 10-8, page 570).

14. Remove the gear assembly from the left frame assembly (Asm-Index: 10-11, page 570).

15. Remove the drive bearing left from the gear assembly.


Replacement1. Place the drive bearing left in the paper handling gear assembly.2. Place the gear assembly in the left frame assembly inserting the shaft of the registration clutch assembly

into the drive bearing left.3. Secure the gear assembly to the left frame using three screws (silver, 6mm).4. Hook all the wires and harnesses to the clamp on the gear assembly.

Attention: Route the wires and harnesses to keep from touching the gears.5. Reconnect J131 of the high harness assembly to the registration clutch assembly.6. Replace the MCU PWB.7. Replace the duplex interface PWB (See page 524).

8. Reconnect J180 of the fuser cover harness to the duplex interface PWB (Asm-Index: 12-6, page 575).







Registration Clutch AssemblyAsm-Index: 10-9, page 570.




hc2m4a3f1

Figure 64. Registration Clutch Assembly Removal







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).



Main Gear AssemblyAsm-Index: 10-10, page 570.




hc2m4a4f

1

2

Figure 65. Main Gear Assembly Removal







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).




15. Remove the MCU PWB (See page 526) together with MCU holder (Asm-Index: 12-9, page 575).

16. Remove the main motor (See page 489).

17. Remove the paper handling gear assembly (See page 492) together with the drive bearing left(Asm-Index: 10-8, page 570).

18. Remove the registration clutch assembly (See page 495).

19. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) to a right angle and hold it in yourhand to keep from closing without the force of the pop up spring left/right (Asm-Index: 11-6 and 11-7,page 572) in the next step.

20. Release the pop up spring left and right from the rear tie plate (Asm-Index: 10-5, page 570) using pliers.

21. Close the Pop up/ROS assembly.22. Remove the eight screws securing the rear tie plate (Asm-Index: 10-5, page 570).

23. Remove the four screws (1) securing the main gear assembly (2) to the left frame assembly (Asm-Index:10-11, page 570).


24. Slide the main gear assembly to the right and release gears and shafts from the frame. If you are havingtrouble removing the main gear assembly, remove the CRU guide assembly left (See page 506).

25. Pull the gear assembly up and behind to remove it from the frame.



Pop Up UnitAsm-Index: 11-1 ∼11-23, page 572.

FRONT

J12 J17

hc2m977f

87

43

2

9

9

1

56

Figure 66. Pop Up Unit Removal (2)










10. Disconnect J12 of the ROS harness (Asm-Index: 12-16, page 575) and J17 of the CRU sensor assembly(Asm-Index: 11-15, page 572) from the MCU PWB (Asm-Index: 12-8, page 575).

11. Remove the ferrite core 1 (1) (Asm-Index: 12-21, page 575) from the harnesses using a small flat bladescrewdriver

12. Remove the screw (2) securing the pop up earth wire (3) (Asm-Index: 11-25, page 572) to the pop upframe (4) (Asm-Index: 11-1, page 572).

Note: The screw securing the other end of the pop up earth wire to the left frame assembly (Asm-Index:10-11, page 570) does not need to be removed.

13. Remove the screw (5) securing the clamp P (6) (Asm-Index: 12-22, page 575) to the left frame assemblyand release the ROS harness and the harness of the CRU sensor assembly

14. Release the ROS harness and the harness of the CRU sensor assembly from the opening in the leftframe.


Attention: Do not touch the surface of the BTR assembly (Asm-Index: 6-1, page 559), the detack saw of thetransport chute assembly (Asm-Index: 6-2, page 559) and the window of the ROS assembly (Asm-Index:11-20, page 572) during the following step.

15. Open the Pop up/ROS assembly and hold it even, the spring force is released in next step.16. Release the pop up spring left (7) /right (8) (Asm-Index: 11-6 and 11-7, page 572) from the rear tie plate


17. Close the Pop up/ROS assembly.18. Remove the two screws (9) securing the pop up shaft (Asm-Index: 11-2, page 572) to the left frame

assembly and the right frame assembly (Asm-Index: 10-4, page 570) respectively.

19. Lift the Pop up/ROS assembly and slide it along the guide channel and remove the pop up unit from theprinter frame.


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


CRU Sensor AssemblyAsm-Index: 11-15, page 572.

J17P/J171

hc2m4b3f

1

2

Figure 67. CRU Sensor Assembly Removal


RemovalNote: If you can access the four mounting screws, you may be able to avoid complete removal of the Pop

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









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.


CRU Guide Assembly LeftAsm-Index: 11-30, page 572.

1

1

26

3 4

6

6

5

hc2m4b7f

Figure 68. CRU Guide Assembly Left Removal








8. Remove the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).


10. Remove the center screw (1) of the HVPS (Asm-Index: 12-11, page 575) securing the HVPS to the CRUguide assembly left (2).

11. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during theoperation below.

12. Remove the two screws securing the left and right pop up latch feet (Asm-Index: 11-22, page 572) to theleft and right pop up latches (Asm-Index: 11-10 and 11-11, page 572).

13. Flex the left and right pop up latches and remove the left and right pop up latch feet.14. Open the Pop up/ROS assembly.

Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) or thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.



16. Remove the screw (3) securing the earth plate left (4) (Asm-Index: 11-32, page 572) on the top of theCRU guide assembly left.

17. Remove the screw (5) securing the upper part of the CRU guide assembly left.18. Remove the six screws (6) securing the CRU guide assembly.19. Press the pins on the left side of the left frame assembly (Asm-Index: 10-11, page 570) to release the

guide assembly.

20. Remove the guide assembly by carefully working it away from the printer frame.

Replacement1. Open the Pop up/ROS assembly and hold it open during the operation below.

Attention: Do not touch the detack saw of the transport chute assembly or the window of the ROS assemblyduring the following steps.

2. Place the CRU guide assembly left on the left frame assembly inserting the pins on the guide assemblyinto the openings in the printer frame.

3. Secure the guide assembly using six screws (silver, 8mm).4. Secure the upper part of the guide assembly using a screw (gold, 14mm).5. Secure the earth plate left using a screw (silver, 6mm)6. Replace the BTR assembly (See page 466).

7. Half close the Pop up/ROS assembly.8. Flex the pop up latch left/right and place the left and right pop up latch foot on the latch left/right. You

may rotate the latch foot to position it properly.9. Secure the left and right pop up latch foot to the pop up latch left/right using two screws (gold,

self-tapping, 10mm).10. Close the Pop up/ROS assembly.


Attention: Ensure that the earth plate left contacts the pop up frame (Asm-Index: 11-1, page 572).

11. Secure the HVPS to the guide assembly using a screw (gold, self tapping, 8mm) on the center of theHVPS.


13. Replace the BTR assembly (See page 466).

14. Replace the front in tray (See page 455) together with the front tray assembly.








CRU Guide Assembly RightAsm-Index: 11-31, page 572.



hc2m4b8f

12

43

4 4

Figure 69. CRU Guide Assembly R Removal







9. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during theoperation below.

10. Remove the BTR assembly (See page 466) to protect from damage.

Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.

11. Remove the screw (1) securing the earth spring right (2) (Asm-Index: 11-33, page 572) to the CRU guideassembly right (3) and remove the spring.

12. Remove the five screws (4) securing the rear left end and front left side of the guide assembly.13. Press the pins on the right side of the right frame assembly (Asm-Index: 10-4, page 570) to release the

guide assembly.

14. Remove the guide assembly from the printer frame.


Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROSassembly during the following steps.

2. Place the guide assembly on the right frame assembly inserting pins on the guide assembly into theopenings.


3. Secure the guide assembly using five screws (silver, 8mm).4. Secure the earth spring right to the guide assembly using a screw (gold, collared, 12mm).5. Replace the BTR assembly (See page 466).

6. Close the Pop up/ROS assembly.

Attention: Ensure that the earth spring right contacts the pop up frame (Asm-Index: 11-1, page 572).

7. Replace the front in tray (See page 455) together with the front tray assembly (Asm-Index: 5-1, page557).








Interlock SwitchAsm-Index: 12-1, page 575.


J21J123

1 2

hc2m4c1f

Figure 70. Interlock switch Removal










11. Remove the CRU guide assembly left (See page 506).

12. Disconnect J123 of the interlock switch (1) from the LVPS assembly (Asm-Index: 12-4, page 575) andJ21 of the interlock switch on the MCU PWB (Asm-Index: 12-8, page 575) and release the harnessesfrom the clamps.

13. Open the Pop up/ROS assembly (Asm-Index: 11-1∼11-23, page 572) and hold it open during thefollowing steps.

Attention: Do not touch the detack saw of the transport chute assembly (Asm-Index: 6-2, page 559) and thewindow of the ROS assembly (Asm-Index: 11-20, page 572) during the following steps.

14. Remove the screw (2) securing the interlock switch (Asm-Index: 12-1, page 575) to the left frameassembly (Asm-Index: 10-11, page 570).

15. Release the harness through the opening in the printer frame and remove the interlock switch from theframe.



Attention: Do not touch the detack saw of the transport chute assembly and the window of the ROSassembly during the following steps.

2. Insert the harness through the opening in the left frame assembly and place the interlock switch on theframe matching the position of the pin on the frame to the hollow on the switch.

3. Secure the interlock switch to the frame using a screw (gold, 12mm).

Attention: Ensure that the arm on the pop up frame presses the interlock switch when the Pop up/ROSassembly closes.

4. Reconnect J123 of the interlock switch to the LVPS and J21 of the interlock switch to the MCU PWB andattach the harnesses to the clamps.

5. Replace the CRU guide assembly left (See page 506).


7. Replace the BTR assembly (See page 466).

8. Replace the front in tray (See page 455) together with the front tray assembly.








Fuser Cover SwitchAsm-Index: 12-2, page 575.



hc2m4c2f

2

1

J190

12

J190

Figure 71. Fuser Cover switch Removal


4. Remove the fan.5. Remove the fan duct.6. Using a flat-bladed screwdriver, squeeze the hooks securing the switch to the printer frame.7. Disconnect J190 of the fuser cover harness (Asm-Index: 12-13, page 575) from the fuser cover switch

(Asm-Index: 12-2, page 575) and remove the switch.

Replacement1. Press the cover switch up into the opening until the switch snaps into place.2. Reconnect J190 of the fuser cover harness to the fuser cover switch.3. Replace the fan duct.4. Replace the fan.5. Replace the left top cover (See page 402).


Attention: Ensure that the fuser cover assembly (Asm-Index: 1-1, page 548) pushes the tab of the fusercover switch when the cover is closed.


FanAsm-Index: 12-3, page 575.

J122

2

1

hc2m3c3f

Figure 72. fan Removal







7. Disconnect J122 of the fan (1) from the LVPS assembly (Asm-Index: 12-4, page 575) and remove theferrite core1 (Asm-Index: 12-21, page 575) from the harness.

8. Release the harness of the fan from clamp and opening.9. Remove the two screws (2) securing the fan to the printer frame.

10. Remove the fan.

Replacement1. Place the fan in the printer frame so the label faces out, so that the air blows out.2. Secure the fan to the printer frame using two screws (silver, collared, 10mm).3. Reconnect J122 of the fan to the LVPS assembly and reinstall the ferrite core1 into the ROS harness

(Asm-Index: 12-16, page 575), the harness for the CRU sensor assembly (Asm-Index: 11-15, page 572),the fuser cover harness (Asm-Index: 12-13, page 575) and the harness to the fan.

4. Route the harness of the fan hanging to clamp and passing through opening so as not to interfere withgears and without slack.





LVPS AssemblyAsm-Index: 12-4, page 575.

6

3

1

4

5

2

8 9 10

7

7

J122 J127

J126

J123

J121

hc2m4C4F

Figure 73. LVPS Assembly Removal


RemovalNote: The small fan shown in Figure 73 may not be on later versions of the printer.

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





7. Disconnect all the connectors from the LVPS assembly.8. Release all the harnesses and the wire from their clamps.9. Remove the screw (1) securing the grounding wires to the printer frame.

Attention: Do not move the parts far, since the power inlet and the LVPS assembly (2) are connected bywires.10. Remove the three screws (3) securing the inlet holder (4) (Asm-Index: 12-5, page 575) to the left frame


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.


Duplex Interface PWBAsm-Index: 12-6, page 575.

J180

2

1hc2m4c5f

Figure 74. Duplex Interface PWB Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the fuser cover.3. Remove the left top cover (See page 402).




7. Disconnect J180 of the fuser cover harness (Asm-Index: 12-13, page 575) from the duplex interface PWB(1).

8. Remove the two screws (2) (silver, hexagon, 8mm) securing the rear end of the duplex interface PWB tothe left frame assembly (Asm-Index: 10-11, page 570).

9. Pull out the duplex interface PWB to the left to disconnect P/J18 from the MCU PWB (Asm-Index: 12-8,page 575).

10. Remove the duplex interface PWB.



MCU PWB without MCU HolderAsm-Index: 12-8, page 575.

hc2m4c6f

2

4

3

1

Figure 75. MCU PWB Removal (1)


RemovalNote: If possible, print a CONFIG page before replacing the MCU (see “Configuration Page” on page 250).

After replacing the MCU, the page count value will be reset to 0. This means that the true printer pagecount will be the value before MCU replacement plus the value shown on the CONFIG page afterreplacement.

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





7. Disconnect all the connectors from the MCU PWB (1) (Asm-Index: 12-8, page 575).

8. Remove the four screws (2).9. Remove the MCU PWB.

Replacement1. Position the MCU PWB in the holder.2. Secure the MCU PWB to the frame using three screws.3. Secure two clamp Fs to the MCU PWB using a screw.4. Reconnect all the connectors to the MCU PWB.5. Route the harnesses to keep from touching the gears and edge of the frame.6. Replace the duplex interface PWB (See page 524).






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.


MCU PWB with MCU HolderAsm-Index: 12-8 and 12-9, page 575.

hc2m4c7f

3

1

2

2

2

Figure 76. MCU PWB Removal (2)


RemovalNote: If possible, print a CONFIG page before replacing the MCU (see “Configuration Page” on page 250).

After replacing the MCU, the page count value will be reset to 0. This means that the true printer pagecount will be the value before MCU replacement plus the value shown on the CONFIG page afterreplacement.

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






Note: The models equipped with the controller inside the printer do not use the connectors P19 andP23. The models equipped with the controller outside of the printer do not use connector P23.

8. Disconnect all the connectors from the MCU PWB (1).9. Release all the harnesses from the clamp and the clamp Fs (Asm-Index: 12-23, page 575) on the MCU

holder.

10. Remove the four screws (2) securing the MCU holder (3) to the left frame assembly (Asm-Index: 10-11,page 570).

11. Remove the MCU PWB together with the MCU holder.


Replacement1. Keeping the harness for P/J13 to the printer frame side from the MCU PWB, place the MCU PWB on the

left frame assembly together with the MCU holder.2. Secure the MCU holder to the frame using four screws (gold, 6mm).3. Reconnect all the connectors to the MCU PWB.4. Hook the harnesses to the clamp and the clamp Fs on the MCU holder.5. Route the harnesses to keep from touching the gears and edge of the frame.6. Replace the duplex interface PWB (See page 524).






Note: Steps 12 and 13 are applicable if you installed a new MCU PWB.

12. Set the NVRAM data according to the specification of the printer.13. Reset the Toner and Fuser counters to 0 (see “Counters” on page 255).


HVPSAsm-Index: 12-11, page 575.



DTS

TR

J151

hc2m4c8f

1

3

3

34

2

Figure 77. HVPS Removal




6. Disconnect all the connectors from the HVPS (1).

Attention: Do not touch the adjustment knob on the HVPS. Do not deform the spring plate on the CRU guideassembly left (Asm-Index: 11-30, page 572).

7. Remove the screw (2) securing the center of the HVPS to the CRU guide assembly left.8. Remove the four screws (3) securing the HVPS to the left frame assembly (Asm-Index: 10-11, page 570).

9. Remove the DTS and interlock cable holders from the front left frame.10. Holding the adjustment knob (4) (Asm-Index: 12-12, page 575) in your fingers, remove the HVPS from

the frame.

11. Remove the adjustment knob from the HVPS.

Replacement1. Place the adjustment knob on the HVPS.

Attention: Do not change the adjustments on the HVPS. Do not deform the spring attachment on the CRUguide assembly left.

2. Holding the volume knob in your fingers, place the HVPS in the left frame assembly.3. Secure the HVPS to the frame using four screws (6mm).

Attention: Ensure that the spring plate on the CRU guide assembly left touches the terminal on the HVPS.4. Secure the center of the HVPS to the CRU guide assembly left using a screw (gold, 8mm).5. Reconnect all the connectors to the HVPS.6. Route harnesses to keep from touching the gears and frame edges.7. Replace the controller assembly (See page 535).


Controller AssemblyAsm-Index: 13-1, page 578.


4

Œ „ |Œ „ |

2

4hc2m4d1f

3

4

1

J31

J31

4

5

Figure 78. Controller Assembly Removal




5. Disconnect J126 from the LVPS assembly (See Figure 73 on page 521).

6. Remove the three screws (2) securing the controller upper cover plate (3) (Asm-Index: 13-9, page 578) tothe printer frame.

7. Remove the six screws (4) securing the controller assembly to the left frame assembly (Asm-Index: 10-11,page 570).

8. Remove the controller assembly so that the controller harness (Asm-Index: 13-5, page 578) passes theopening in the frame.

Note: J31 is disconnected by removing the controller assembly from the left frame assembly.



Controller PWBAsm-Index: 13-6, page 578.



hc2m4d2f

3

3

2

4

15

5

Figure 79. Controller PWB Removal





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


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.



Controller PWB SIMM

RemovalAttention: Follow the instructions for handling static-sensitive devices described on page 20.

1. Switch off printer power and unplug the power cord from the wall.2. Remove the left cover assembly (See page 406).

3. Locate the correct socket group for the type of SIMM you are installing. There are two socket groups: onecontains three sockets, the other contains four sockets. The DRAM SIMMs (memory) must are in one of

45°

hc2m133F

Flash memory,IPDS SIMMs

DRAM SIMMs

Notch

Notch

Figure 80. Controller PWB SIMM Removal


the sockets in the socket group of three. The IPDS SIMM and the flash memory SIMMs (including theController SIMM with the operating system, PCL and PS) are in one of the sockets in the socket group offour.SIMMs should be loaded from the left to the right but the position of the SIMM within the group of socketsdoes not matter.

4. Using your thumbs, press with even pressure on both ends of the clips until the SIMM is released. Pivotthe SIMM 45 degrees and remove it from the socket.



Network Interface Card

RemovalAttention: Follow the instructions for handling static-sensitive devices described on page 20.

1. Switch off printer power and unplug the power cord from the wall.2. Move to the back of the printer. Two slots for interface cards are located at the right side of the back of the

printer.3. Loosen and remove the thumbscrews that hold the network interface cards.4. Slide the card from the slot guides, pulling slowly, and remove it from the printer.

hc2m134F

Figure 81. Network Interface Card Removal


Chapter 7. Preventive Maintenance and Usage KitPreventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543Usage Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543Reconditioning Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543

Preventive MaintenanceThere is no preventive maintenance for the IBM InfoPrint 20.

Usage KitThe parts included in this kit should all be replaced approximately every 200K prints. The failure of these partscan impair printer performance. The customer is responsible for replacing the Usage Kit.

See “Appendix B. Supplies” on page 591 for ordering information and part numbers.

See the “IBM InfoPrint 20: User’s Guide” for replacement instructions.

Reconditioning KitThere is no reconditioning kit for the IBM InfoPrint 20.


Chapter 8. Parts CatalogHow to Use the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546

Assembly-Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546Grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546Part Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .547

Assembly Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548Assembly 1: Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548Assembly 2: Paper Cassette. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550Assembly 3: Paper Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .553Assembly 4: Paper Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .555Assembly 5: Multi-Sheet Inserter (Auxiliary Tray) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557Assembly 6: Paper Transportation I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559Assembly 7: Paper Transportation II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .562Assembly 8: Fuser and Paper Exit I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .564Assembly 9: Fuser and Paper Exit II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567Assembly 10: Fuser and Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .570Assembly 11: Pop Up and Xerographics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572Assembly 12: Electrical I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575Assembly 13: Electrical II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578Assembly 99: Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580Assembly 100: Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .585

Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587Commonly Used Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587Commonly Used Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588


Cleaners and Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588

Chapter 8. Parts Catalog 545

How to Use the Parts CatalogThe parts catalog illustrations and tables show and list all parts of the associated assembly. Below is anexample of these tables with an explanation.

Asm–Index Grid

PartNumber Units Description

1– NP Cover asm.

–1 B2 90H0000 1 v Cover, delivery

–2 C1 90H0001 1 v Hinge, stopper (with 1-3 and 1-4)

–3 C2 NP 1 v v Guide, left

–4 C1 NP 1 v v Cover, block, front

Assembly-IndexAll parts of assembly number 1 are listed in this column. The numbers 1, 2, 3, and 4, and so forth refer tothe corresponding numbers in the illustration for this assembly.

Index number 2, part number 90H0001, is a subassembly of assembly 1. Notice that index number 2includes two parts, 3 and 4. These parts cannot be ordered individually. If one is needed, order thesubassembly, index number 2.

GridEach parts illustration is divided into grids. The grids are labeled A, B, C, and D vertically and 1, 2, and 3horizontally. The combination of a vertical grid (such as C) and a horizontal grid (such as 1) provides thecoordinates C1. The index number of the part will be located in the C1 area.


Part NumberThis is the IBM part number. NP (non procurable) means the part or assembly cannot be ordered.

UnitsThe number in this column represents the number of usages of that part in this assembly.

DescriptionThis is a description of the assembly or part.


Assembly Locations

Assembly 1: Covers

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m301F


Table 66. Assembly 1: Covers

Asm–Index Grid


1– Covers

–2 A3 90H0754 1 Fuser cover

–3 A3 90H0755 1 Fuser cap cover

–4 A2 90H3329 1 Left top cover

–5 B4 90H3383 1 Right top cover

–6 B1 07L0038 1 Left cover assembly (with 1-7, 1-8)

–7 B1 NP 1 v Left side cover

–8 B2 NP 1 v Controller shield

–9 C1 90H0759 1 Left lower cover

–10 C4 90H0760 1 Right cover assembly

–11 C1 90H0761 1 Front side cover

–12 B4 90H0762 1 Exit cover

–14 A2 90H0763 1 Pop up upper cover

–15 B2 90H0764 1 Pop up lower cover

–16 A2 90H0765 1 Exit extent tray

–17 A2 90H0766 1 Tray stopper

–18 A1 90H3466 1 Console assembly and Overlay

–19 A1 90H0768 1 Console ground wire (Early models only)

Asm–Index numbers not used: 1, 13


Assembly 2: Paper Cassette

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m302F1 (with 2-24)


Table 67. Assembly 2: Paper Cassette

Asm–Index Grid


2– Paper cassette

–1 C1 90H0719 1 A3 Long cassette assembly (with 2-2∼2-24)

–1 C1 90H0718 1 A4 Short cassette assembly (with 2-2∼2-24)

–2 B3 NP 1 v Cassette housing

–3 C4 NP 1 v Cassette bottom cover

–4 A2 NP 1 v Side guide grip

–5 A3 NP 2 v Snubber guide

–6 A2 NP 1 v Side guide assembly L

–7 A3 NP 1 v Side guide assembly R

–8 C2, C3 NP 2 v Rack gear

–9 C3 NP 1 v Pinion gear

–10 A1 NP 1 v Bottom plate assembly

–11 A1 NP 1 v Normal force spring plate

–12 A1, A2 NP 2 v Cassette side normal force spring

–13 B1 NP 1 v Cassette normal force spring

–14 B2 NP 1 v End guide plate

–15 A2 NP 1 v Paper end guide

–16 A2 NP 1 v End guide spring

–17 A2 NP 1 v End guide

–18 C2 NP 1 v Pivot plate


Table 67. Assembly 2: Paper Cassette (continued)

Asm–Index Grid


2– Paper cassette

–19 C2 NP 1 v Sector gear

–20 B1 NP 1 v Size cam

–21 B2 NP 1 v Locking pin

–22 B1 NP 1 v Cassette latch L

–23 C3 NP 1 v Cassette latch R

–24 B1, B3 NP 2 v Cassette latch spring

–25 C1 90H0770 1 A3 Cassette cover

–25 C1 90H3467 1 A4 Cassette cover


Assembly 3: Paper Feeder I

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m303F

6 (with 7-12, 18)


Table 68. Assembly 3: Paper Feeder I

Asm–Index Grid


3– Paper Feeder

–1 A4 90H0771 1 Feeder PWB

–2 B4 90H0772 1 Feeder harness (Tray Lower)

–4 C2 90H0773 1 Turn in chute

–5 C2 90H0774 1 Turn chute assembly

–6 B3 90H0775 1 Cassette guide assembly left (with 3-7∼3-12, 3-18)

–7 B4 NP 1 v Cassette guide L

–8 C4 NP 4 v Size actuator

–9 B4 NP 1 v Size actuator spring

–10 B3 NP 1 v Low paper actuator

–11 C3 90H0776 1 v MSI/Cassette no paper sensor

–12 C4 NP 1 v Feeder harness

–18 C3 NP 1 v Cassette guide cap

–13 B1 90H0777 1 Cassette guide assembly right (with 3-14, 3-15)

–14 B2 NP 1 v Cassette guide R

–15 B2 NP 1 v Cassette stopper spring

–16 B2 90H0778 1 Cassette no paper actuator



Assembly 4: Paper Feeder II

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m304F


Table 69. Assembly 4: Paper Feeder II

Asm–Index Grid


4– Paper feeder II

–1 C2 4 Feed roll (in kit P/N 90H0779) (see page 580)

–2 C2 90H0780 1 Feed shaft assembly

–3 B4 1 Feed core (in kit P/N 90H0781) (see page 580)

–4 B4 1 Feed core spring (in kit P/N 90H0781) (see page 580)

–5 B4 1 Feed gear (in kit P/N 90H0781) (see page 580)

–6 A3, B1 2 Feed bearing (in kit P/N 06L9997) (see page 580)

–7 B4 1 Feed spring (in kit P/N 90H0781) (see page 580)

–8 A4 90H0782 1 Feed solenoid

–9 B4 90H0783 1 Electromagnetic clutch

–10 C2 90H0784 1 Turn roll assembly

–11 C2 90H0785 1 Rear roll assembly

–12 B4 2 Turn gear (in kit P/N 90H3384) (see page 580)

–13 A1, B1,B3, B4

90H0786 4 Turn bearing

–14 B3 1 Turn idler gear (in kit P/N 90H3384) (see page 580)

–15 B4 1 Feed idler gear (in kit P/N 90H3384) (see page 580)

–16 C4 2 Out idler gear (in kit P/N 90H3384) (see page 580)


Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)

7 (with 8-17)

13 (with 14-17)

hc2m305F

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 70. Assembly 5: Multi-Sheet Inserter (Auxiliary Tray)

Asm–Index Grid


5– Multi-Sheet Inserter

–1 C2 90H0790 1 Front tray assembly (with 5-2, 5-3)

–2 C2 NP 1 v Front tray cover

–3 C2 NP 1 v Front extent tray

–4 C3 90H0791 1 Front in tray

–5 A1 90H0792 1 Front bottom tray

–6 A3 2 Normal force spring (in kit P/N 90H3380) (see page 580)

–7 B4 90H0793 1 MSI Bracket assembly (with 5-8∼5-17)

–8 B4 NP 1 v Sensor bracket

–9 A4 90H0776 1 v MSI No paper sensor (same as 3-11)

–10 A4 90H0794 1 v MSI No paper actuator

–11 A4 NP 1 v MSI actuator holder

–12 A4 NP 1 v MSI no paper harness

–13 A3 90H0795 1 v Toner sensor assembly (with 5-14∼5-17)

–14 A3 NP 1 v v Toner sensor

–15 A3 NP 1 v v Toner sensor holder

–16 A3 NP 1 v v Toner sensor spring

–17 A3 NP 1 v v Toner sensor harness


Assembly 6: Paper Transportation I

1 2 3 4

1 2 3 4

A

B

C

A

B

C

8 (with 9-13)

2 (with 3-19)

hc2m306F


Table 71. Assembly 6: Paper Transportation I

Asm–Index Grid


6– Paper transportation I

–1 A2 90H0796 1 BTR assembly (Supply Item - Included in Usage Kit)

–2 A3 90H0797 1 Transport chute assembly 100/110V (with 6-3∼6-19)

–2 A3 90H3421 1 Transport chute assembly 220V (with 6-3∼6-19)

–3 B4 NP 1 v Transport sub assembly (same as 7-1)

–4 A4 NP 1 v Connector bracket2

–5 A4 11L5354 1 v High harness assembly (100V/110V)

–5 A4 11L6539 1 v High harness assembly (220V)

–6 A3 NP 1 v Transport out plate

–7 B2 NP 1 v Transport front chute

–8 C3 NP 1 v Pick up roll assembly (with 6-9∼6-13)

–9 C3 90H0798 2 v v Pick up roll

–10 C2, C3,C4

NP 3 v v Core roll

–12 C2, D4 NP 2 v v Pick up cam

–13 C3 NP 1 v v Pick up shaft

–14 C4 NP 1 v Transport bearing

–15 C2 1 v Pick up gear (in kit P/N 90H3384) (see page 580)

–16 C2 1 v Pick up spring (in kit P/N 90H3380) (see page 580)

–17 B2 90H0799 1 v Pick up solenoid


Table 71. Assembly 6: Paper Transportation I (continued)

Asm–Index Grid


6– Paper transportation I

–18 B2 1 v Retard pad (in kit P/N 90H0800) (see page 580)

–19 B3 2 v Retard pad spring (in kit P/N 90H0800) (see page 580)

Asm–Index numbers not used: 11


Assembly 7: Paper Transportation II

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m307F

1 (with 2-19)


Table 72. Assembly 7: Paper Transportation II

Asm–Index Grid


7– Paper transportation II

–1 B2 NP 1 Transport sub assembly (with 7-2∼7-19) (same as 6-3)

–2 B3 NP 1 v Transport housing assembly

–3 A2, A4 11L5337 2 v BTR bearing

–4 A2 1 v BTR spring left (in kit P/N 90H3380) (see page 580)

–5 A4 1 v BTR spring right (in kit P/N 90H3380) (see page 580)

–6 A2 1 v Registration sensor (in kit P/N 90H3290) (see page 580)

–7 A2 1 v Registration actuator (in kit P/N 90H3290) (see page 580)

–8 A3 1 v Registration spring (in kit P/N 90H3290) (see page 580)

–9 A3 1 v Registration sensor bracket (in kit P/N 90H3290) (see page 580)

–10 C2 90H3291 1 v Metal registration roll

–11 B2 90H3292 1 v Rubber registration roll

–12 B1 1 v Registration in gear (in kit P/N 90H3384) (see page 580)

–13 C3 1 v Registration back gear (in kit P/N 90H3384) (see page 580)

–14 C3 1 v Registration front gear (in kit P/N 90H3384) (see page 580)

–15 B1, C3 2 v Registration front bearing (in kit P/N 06L9997) (see page 580)

–16 B1, B3 2 v Registration back bearing (in kit P/N 06L9997) (see page 580)

–17 B2 07L0044 1 v Registration spring left

–18 B3 07L0044 1 v Registration spring right

–19 C2 90H3293 1 v Rear chute assembly


Assembly 8: Fuser and Paper Exit I

26

hc2m308F

28

2 7

1 (with 2-28)

10 (with 11-14)

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 73. Assembly 8: Fuser and paper exit I

Asm–Index Grid


8– Fuser and paper exit

–1 A3 90H3465 1 Fuser sub-assembly 100V (with 8-2∼8-28, including BTR Assembly 90H0796)Supply



–2 C3 NP 1 v Fuser sub assembly (same as 9-1)

–3 B2 NP 1 v Fuser cover L

–4 C4 NP 1 v Fuser cover R

–5 A1 NP 1 v Fuser label assembly

–6 A1 NP 1 v Fuser top cover assembly

–7 A2 NP 1 v Full stack sensor

–8 A2 NP 1 v Full stack actuator

–9 A2 1 v Full stack spring (in kit P/N 90H3380) (see page 580)

–10 A3 NP 1 v Fuser rear assembly (with 8-11∼8-14)

–11 A3 NP 1 v v Fuser rear cover

–12 A2 NP 1 v v Exit eliminator

–13 B2 NP 1 v v Eliminator plate L

–14 B2 NP 1 v v Eliminator plate R

–15 B2 NP 1 v Exchange chute


Table 73. Assembly 8: Fuser and paper exit I (continued)

Asm–Index Grid


8– Fuser and paper exit

–16 B3 NP 1 v Exchange lever

–17 B3 NP 1 v Exchange spring

–18 C4 NP 1 v Exit chute

–19 C4 NP 1 v Finger bracket

–20 B3, B4 NP 6 v Size cam

–21 B3, B4 NP 6 v Heat roll finger

–22 B4 NP 6 v Exit chute roll

–23 B4 NP 1 v Exit torsion spring

–24 B4 NP 1 v Exit actuator

–25 C2 NP 1 v Exit sensor

–26 C2 NP 1 v Exit sensor clip

–27 B2 NP 1 v Clip

–28 A3 NP 1 v Cover


Assembly 9: Fuser and Paper Exit II

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m309F

1 (with 2-34)


Table 74. Assembly 9: Fuser and Paper Exit II

Asm–Index Grid


9– Fuser and Paper Exit II

–1 A4 NP 1 Fuser sub assembly (with 9-2∼9-34) (same as 8-2)

–2 C3 NP 1 v Fuser frame assembly

–3 A2 NP 1 v Connector bracket1

–4 A1 NP 1 v Fuser harness

–5 A2 NP 1 v Heater assembly

–6 C3 NP 1 v Lamp guide

–7 B3 NP 1 v Thermal fuse

–8 B2 NP 1 v Thermostat

–9 B3 NP 1 v Temperature sensor assembly

–10 A2 NP 1 v Heat roll

–11 B1, C3 NP 1 v Heat roll ring

–12 B1 NP 1 v Heat roll bearing L

–13 C3 NP 1 v Heat roll bearing R

–14 C3 NP 1 v Heat roll diode

–15 A4 NP 1 v Pressure roll

–16 A3, A4 NP 2 v Pressure roll bearing

–17 A3, A4 NP 2 v Nip spring

–18 A3 NP 1 v Nip lever L

–19 A4 NP 1 v Nip lever R


Table 74. Assembly 9: Fuser and Paper Exit II (continued)

Asm–Index Grid


9– Fuser and Paper Exit II

–20 C1 NP 1 v Pressure roll eliminator

–21 B3 NP 1 v Pressure roll earth plate

–22 C2 NP 1 v Fuser inlet chute

–23 C1 NP 1 v Heat roll idler gear

–24 C1 NP 1 v Heat roll idler flange

–25 B1 NP 1 v Heat roll idler shaft

–26 B1 NP 1 v Heat roll gear

–27 B1 NP 1 v Exit idler gear

–28 B1 NP 1 v Exit idler shaft

–29 B1 NP 1 v Exit gear

–30 B1 NP 1 v Exit bearing

–31 C1 NP 1 v Exit roll assembly

–32 B3 NP 1 v STS plate

–33 B3 NP 2 v Pad

–34 B2 NP 1 v Clip


Assembly 10: Fuser and Drive

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m310F


Table 75. Assembly 10: Fuser and Drive

Asm–Index Grid


10– Fuser and drive

–2 C2 NP 1 Base frame assembly

–4 A1 NP 1 Right frame assembly

–5 A2 NP 1 Rear tie plate

–6 A4 90H3294 1 Main motor

–7 A4 90H3295 1 Paper handling gear assembly

–8 A4 NP 1 Drive bearing L

–9 A4 90H3296 1 Registration clutch assembly

–10 A3 90H3297 1 Main gear assembly

–11 C4 NP 1 Left frame sub assembly

–12 C4 NP 1 Frame bottom plate



Assembly 11: Pop Up and Xerographics

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m311F

20A

20 (with 1-23)


Table 76. Assembly 11: Pop Up and Xerographics

Asm–Index Grid


11– Pop Up and Xerographics

–20 A3 90H3304 1 Pop Up/ROS assembly (with 11–1∼11–23)

–1 A1 NP 1 v Pop up frame

–2 A3 NP 1 v Pop up shaft

–3 A1 90H3298 1 v Fuser guide lever

–4 A2 NP 1 v Pop up bearing L

–5 A2 NP 1 v Pop up bearing R

–6 A2 1 v Pop up spring, left (in kit P/N 90H3380) (see page 580)

–7 A3 1 v Pop up spring, right (in kit P/N 90H3380) (see page 580)

–8 B1 90H3299 1 v Latch lever

–9 A1 NP 1 v Latch shaft

–10 A1 90H3300 1 v Pop up latch, left

–11 B2 90H3301 1 v Pop up latch, right

–12 A1, B2 2 v Pop up latch spring (in kit P/N 90H3380) (see page 580)

–13 A1, A2 NP 2 v CRU latch

–14 A1, A2 2 v CRU latch spring (in kit P/N 90H3380) (see page 580)

–15 B1 90H3302 1 v CRU sensor assembly

–16 A1, A2 NP 2 v ROS spring holder

–17 B1, B2 2 v ROS push spring (in kit P/N 90H3380) (see page 580)

–18 B1 NP 1 v ROS support


Table 76. Assembly 11: Pop Up and Xerographics (continued)

Asm–Index Grid


11– Pop Up and Xerographics

–19 B1 90H3303 1 v Interlock actuator

–20A C1 NP 1 v ROS assembly

–21 A1 NP 1 v Guide arm

–22 B1, B2 90H3305 2 v Pop up latch foot

–23 A2 NP 3 v Pop up clamp

–24 A2 NP 1 Shaft earth wire

–25 A1 NP 1 Pop up earth wire

–26 A2 NP 1 ROS spacer

–30 A4 90H3306 1 CRU guide assembly, left

–31 A4 90H3307 1 CRU guide assembly, right

–32 B3 NP 1 Earth plate L

–33 A4 NP 1 Earth spring R

–40 C2 90H0748 1 EP (Toner) cartridge (Supply Item)

Asm–Index numbers not used: 27 to 29, and 34 to 39


Assembly 12: Electrical I

hc2m312F

43 42

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 77. Assembly 12: Electrical I

Asm–Index Grid


12– Electrical I

–1 A3 90H3308 1 Interlock switch

–2 B1 90H3309 1 Fuser cover switch

–3 A2 90H3310 2 Fan

–4 C3 90H3311 1 Low voltage power supply (100/110V)

–4 C3 90H3312 1 Low voltage power supply (220V)

–5 C2 NP 1 Inlet holder

–6 A3 90H3313 1 Duplex interface PWB

–7 A2 NP 1 Fan duct

–8 C3 07L0039 1 MCU PWB (100V)

–8 C3 90H3314 1 MCU PWB (110V)

–8 C3 07L0040 1 MCU PWB (220V)

–9 B3 NP 1 MCU holder

–10 B3 NP 1 HVPS spacer

–11 A3 90H3315 1 High voltage power supply

–12 A4 NP 1 Knob volume

–13 B2 11L5355 1 Fuser cover harness

–14 C4 90H3316 1 LVPS harness

–15 A4 90H3317 1 HVPS harness

–16 B4 90H3318 1 ROS harness


Table 77. Assembly 12: Electrical I (continued)

Asm–Index Grid


12– Electrical I

–17 C4 90H3319 1 Tray harness

–18 C4 11L5356 1 Toner relay harness

–19 C2 NP 1 Power cord

–20 C2 NP 1 Adapter

–21 B4 NP 1 Ferrite core1

–22 B1 NP 1 Clamp P

–23 C4 NP 2 Clamp F

–40 A1, A2 NP 2 Fan guard

–41 A1 NP 1 Bracket

–42 C4 11L6587 1 Fan, LVPS (7 Amp LVPS Only)

–43 C3 NP 1 Fan mounting bracket

Asm–Index numbers not used: 24 to 39


Assembly 13: Electrical II

1 2 3 4

1 2 3 4

A

B

C

A

B

C

2

9

hc2m313F

3

5

5

7

8

6


Table 78. Assembly 13: Electrical II

Asm–Index Grid


13– Electrical II

–2 A3 90H0703 1 Cage

–3 B2 90H0753 1 Bezel

–5 C1 NP 2 Panel cap

–6 B4 90H0705 1 Controller PWB

–7 C4 07L0041 1 Controller harness

–8 B4 90H3320 1 Console harness

–9 A4 NP 1 Panel



Assembly 99: KitsTable 79. Assembly 99: Kits

Asm–Index Part Number Description

99– Kits

06L9997 Bearing kit

NP v Feed bearing (4-6)

NP v Turn bearing (4-13)

NP v Registration front bearing (7-15)

NP v Registration back bearing (7-16)

NP v Drive left bearing (10-8)

90H3380 Spring kit

NP v Turn chute spring (3-3)

NP v Feed spring (4-7)

NP v MSI normal force spring (5-6)

NP v Pick up spring (6-16)

NP v BTR left spring (7-4)

NP v BTR right spring (7-5)

NP v Full stack spring (8-9)

NP v Pop up spring, left (11-6)

NP v Pop up spring, right (11-7)

NP v Pop up latch (11-12)


Table 79. Assembly 99: Kits (continued)


99– Kits

NP v CRU latch spring (11-14)

NP v ROS push spring (11-17)

90H3384 Gear kit

NP v Turn gear (4-12)

NP v Turn idler gear (4-14)

NP v Feed idler gear (4-15)

NP v Out idler gear (4-16)

NP v Pick up gear (6-15)

NP v Registration in gear (7-12)

NP v Registration front gear (7-13)

NP v Registration back gear (7-14)

11L5322 Hardware kit

NP v Screw ’S’ (machine, collared, 6mm)

NP v Screw ’X’ (self-tapping, collared, 8mm)

NP v Screw ’X’ (machine, collared, 10mm)

v Thumbscrews

11L5321 Duplex bearing kit

NP v Duplex bearing (31-10)

NP v Duplex bearing (31-13)




99– Kits

NP v Pulley gear(31-14)

NP v Duplex collar (31-15)

07L0026 Repack/Relocation kit

NP v Box and packing materials

06L9998 Duplex gear kit

NP v One-way gear (31-17)

NP v Duplex gear D (31-18)

NP v Duplex gear C (31-19)

NP v Duplex gear B (31-20)

NP v Duplex gear A (31-21)

NP v Offset gear (31-22)

90H0781 Feed core kit

NP v Feed core (4-3)

NP v Feed core spring (4-4)

NP v Feed gear (4-5)

NP v Feed spring (4-7)

90H0800 Retard pad kit

NP v Retard pad (6-18)

NP v Retard pad spring (6-19)




99– Kits

90H3290 Registration actuator kit

NP v Registration sensor (7-6)

NP v Registration actuator (7-7)

NP v Registration spring (7-8)

NP v Registration sensor bracket (7-9)

90H3478 Rear cover kit

NP v Rear cover (42-2)

NP v Spring (42-4)

NP v Paper chute (42-5)

NP v Strap (42-33)

90H3479 Transport roll kit

NP v Transport roll (42-7)

NP v Right hand lock (42-8)

NP v Left hand lock (42-24)

NP v Spacer (42-35)

NP v E-ring

NP v KL-Clip

90H3480 Feed roller kit

NP v Feed roller (42-14)




99– Kits

NP v Feed roller bracket (42-15)

NP v Right hand feed roller bracket (42-16)

NP v Left hand feed roller bracket (42-17)

11L5352 Kit connector kit

NP v Connector harness (42-30)

NP v Screw (42-31)


Assembly 100: FirmwareTable 80. Assembly 100: Firmware


100– Firmware

–1 90H0705 Controller

–2 90H0703 Cage

–3 90H0753 Bezel

–4 11L5325 PCL/PS SIMM (8MB)

–5 11L5326 IPDS SIMM

–7 11L5327 Twinax card

–8 11L5328 Coax card

–9 63H2837 Ethernet card

–10 63H2834 T/R card

–11 90H0610 Hard drives

–12 63H2443 Macro flash (2MB)

–13 63H2444 Macro flash (4MB)

–14 63H2463 DRAM (4MB)

–15 63H2465 DRAM (8MB)

–16 63H2467 DRAM (16MB)

–17 63H2469 DRAM (32MB)

–18 07L0023 PCL SIMM – Simplified Chinese DBCS


Table 80. Assembly 100: Firmware (continued)


100– Firmware

–19 07L0022 PCL SIMM – Traditional Chinese DBCS

–20 07L0021 Japanese Heisei Fonts

–21 11L6581 PAGES/ESCP SIMM (8MB)

–22 11L6624 PCL/PS SIMM (8MB) for 4320-003


Miscellaneous Items

Commonly Used PartsDescription Part Number Asm–Index / Page Units

Pick up roll kit 90H0798 6-8 1

MSI (auxiliary tray) retard (separation) pad 90H0800 6-18 1

MCU PWB 90H3314 12-8 1

Fan 90H3310 12-3 1

Fuser assembly, 100 VAC (supply item) 90H3465 8-1 1



High-voltage power supply assembly 90H3315 12-8 1

Low-voltage power supply, 100/110 VAC 90H3311 12-4 1

Low-voltage power supply, 220 VAC 90H3312 12-4 1

Controller 90H0705 13-6, 100-1 1


Commonly Used FastenersWhere Used Description Part Number

Fan Screw, M3x30, no washer

Internal paper handling Screw, M4x10, black-L9, head

Laser/scanner Screw, M3x20, brass colored

Main motor (MT1) M4x8, formed washer

Metal parts M3x6, formed washer

Plastic parts M3x6, double washer

ToolsThere are no special tools required to service the IBM InfoPrint 20.

Cleaners and LubricantsThe following cleaners and lubricants are approved for use with this printer:

Item Use Part Number Remarks

Cleaner Cleaning metal parts 2286522 Solvent based cleaner

Cover cleaner Cleaning plastic, rubber, and externalparts

6933028 Water based, mild detergent

Grease Lubricating gear teeth 1280441 General purpose grease, mediumweight

Oil Lubricating gear shafts and bearings 1280443 General purpose oil, medium viscosity


Appendix A. FeaturesStandard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589

Standard Featuresv Printing speed of up to 20 pages per minutev Resolution of 600 dots per inch (dpi), switchable to 1200 dpi emulationv PCL5e supportv Adobe PostScript 3v 4MB of memoryv Parallel interface (IEEE Std 1284-1994)v 500-sheet paper trayv 150-sheet auxiliary trayv 500-sheet paper output binv Printer drivers

Optional FeaturesFeature Feature Number Part Number

Duplex Unit 4402 90H0716

Paper Drawer/500-Sheet A4/Letter 4501 90H0717

Paper Drawer/500-Sheet A3/Ledger 4502 90H3341

500-Sheet Tray - A4/Letter 4503 90H0718


Feature Feature Number Part Number

500-Sheet Tray - A3/Ledger 4504 90H0719

2,000 Sheet Input Drawer 4620 90H0720

Envelope Tray 4511 90H0721

Network Card for Token-Ring 4120 06L9835

Network Card for Ethernet 4161 06L9838

IBM IPDS SIMM 4820 90H0746

IBM Coax SCS Interface 4171 06L9846

IBM Twinax SCS Interface 4141 06L9849

4MB Memory SIMM 4304 63H2463




2MB Flash Memory 4030 63H2443

4MB Flash Memory 4032 63H2444

Hard Drive 4320 90H0610

PC Parallel Cable 63H1956

Software CD Kit 90H0749

Operator Panel Overlays 90H3335

6 ft US (Chicago) Line Cord 6952301

Japanese Heisei Font 4810 07L0012

PAGES & ESC/P SIMM 4840 11L6578

Appendix A. Features 590

Appendix B. SuppliesOrdering Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .592

Ordering SuppliesIn the U.S.A. or Canada, order printing supplies from IBM Printer Supplies, 1-888-IBM PRINT(1-888-426-7746).

In Europe, call IBM Supplies Fulfillment Operations at 31-43-3502756, or at one of the following numbers:v Denmark: 80015534v Finland: 08001-13110v France: 05-905871v Germany: 0130 818005v Italy: 1-678 78349v Norway: 800-11389v Sweden: 020-794270v United Kingdom: 0800-968679


Part NumbersThe customer is responsible for buying and replacing the following supplies.

Supply Average Yield Part Number

EP (Toner) Cartridge 14,000 impressions 90H0748

Usage Kit (100 Volt) 200,000 impressions 90H3465



Notes:1. For the EP (Toner) cartridge and usage kits, the approximate average yield has been established with a coverage of 5

percent. An impression is defined as one side of a printed letter-size page with a 1/2″ border around the page. A duplexpage is defined as two impressions.A toner cartridge can print approximately 14,000 pages of Letter-size paper, containing text or graphics that cover 5% of thepage. Depending on the type of printing you do, you can obtain up to double the page yield if you use the ECONO settingfor the QUALITY item on the Config Menu or if you select toner saver print quality mode from your printer driver. (Note thatthe driver setting will override the menu setting.) For example, using ECONO and a density setting of 1, you may be able toprint up to 28,000 images at 5% coverage.Note: The actual page yield is affected by the environment, the type of print media, the percentage of text and graphics,the complexity of the graphics, and other factors.

2. The usage kit includes a fuser assembly and transfer charging (BTR) roller assembly.

Appendix B. Supplies 592

Appendix C. Media SpecificationsAttention:

Please use print materials that conform to the specifications listed in the following sections. Usingnon-conforming print materials can decrease page yield, cause jams, and damage your printer.

The following sections contain information about selecting print materials, including:v “Auxiliary Tray Paper Specifications” on page 595

v “A4/Letter Tray Paper Specifications” on page 598

v “A3/Ledger (11 inches x 17 inches) Tray Paper Specifications” on page 599

v “Envelope Tray Paper Specifications” on page 601

v “2000-Sheet Input Drawer Paper Specifications” on page 601

Notes:

1. The following media weights are supported:v Paper trays: 16-28 pound (60-105 grams/meter²)v Envelope tray: 16-28 pound (60-105 grams/meter²)v Auxiliary tray:

– Paper, labels, transparencies, envelopes: 60-135 grams/meter²– Japanese Official Postcard: 190 grams/meter²

v 2000-Sheet Input Drawer: 16-28 pound paper (60-105 grams/meter²)2. Do not use the following types of paper and printable material in your printer:v Multipart formsv Stapled, folded, or wrinkled paperv Smooth or coated paper


3. Use the auxiliary tray to print transparencies or labels. Do not feed these types of print media from thepaper trays.

4. Some recycled papers release paper dust that can accumulate and cause frequent paper jams andreduced supplies life.

5. High humidity can damage paper. Try to store paper where it is cool and dry.

Appendix C. Media Specifications 594

Auxiliary Tray Paper Specifications

Style Size DuplexShort-edge feed

(SEF)Long-edge feed

(LEF)

Paper

Letter8.5 x 11 in215.9 x 279.4 mm

Yes Yes Yes

Legal8.5 x 14 in215.9 x 355.6 mm

Yes Yes No

Folio8.5 x 13 in215.9 x 330.2 mm

Yes Yes No

11 x 1711 x 17 in279.4 x 431.8 mm

Yes Yes No

A48.27 x 11.69 in210 x 297 mm

Yes Yes Yes

B5-JIS7.16 x 10.12 in182 x 257 mm

No Yes Yes

B410.12 x 14.33 in257 x 364 mm

Yes Yes No

A55.85 x 8.27 in148.5 x 210 mm

No No Yes



(SEF)Long-edge feed

(LEF)

A311.69 x 16.54 in297 x 420 mm

Yes Yes No

Executive7.25 x 10.25 in184.2 x 266.7 mm

No No Yes

Statement5.5 x 8.5 in139.7 x 215.9 mm

No No Yes

Custom formsMinimum:

3.5 x 5.8 in88 x 148 mm

Maximum:13 x 20 in330 x 508 mm

No Yes No

Envelopes and Postcards

Japanese Official Postcard (Hagaki)3.94 x 5.83 in100 x 148 mm

No Yes No

Monarch3.875 x 7.5 in98.4 x 190.5 mm

No Yes No

COM104.125 x 9.5 in104.8 x 241.3 mm

No Yes No



(SEF)Long-edge feed

(LEF)

C56.38 x 11.77 in162 x 229 mm

No Yes No

DL4.33 x 8.66 in110 x 220 mm

No Yes No

Custom envelopesMinimum:

3.5 x 5.8 in88 x 148 mm

Maximum:13 x 20 in330 x 508 mm

No Yes No


A4/Letter Tray Paper Specifications

Style Size

LTR Paper Group A4 Paper Group

Duplex SEF LEF Duplex SEF LEF

Letter8.5 x 11 in215.9 x 279.4 mm

Yes Yes Yes Yes No Yes

A48.27 x 11.69 in210 x 297 mm

Yes No Yes Yes Yes Yes

B5-JIS7.16 x 10.12 in182 x 257 mm

Not supported No No Yes

A55.85 x 8.27 in148.5 x 210 mm



No No Yes Not supported




A3/Ledger (11 inches x 17 inches) Tray PaperSpecifications

Style Size



Letter8.5 x 11 in215.9 x 279.4 mm

Yes Yes Yes Yes No Yes

Legal8.5 x 14 in215.9 x 355.6 mm

Yes Yes No Yes Yes No

Folio8.5 x 13 in215.9 x 330.2 mm


11 x 1711 x 17 in279.4 x 431.8 mm


A48.27 x 11.69 in210 x 297 mm

Yes No Yes Yes Yes Yes

B5-JIS7.16 x 10.12 in182 x 257 mm


B410.12 x 14.33 in257 x 364 mm



Style Size



A55.85 x 8.27 in148.5 x 210 mm


A311.69 x 16.54 in297 x 420 mm







Envelope Tray Paper Specifications


(SEF)Long-edge feed

(LEF)

Monarch3.875 x 7.5 in98.4 x 190.5 mm

No Yes No

COM104.125 x 9.5 in104.8 x 241.3 mm

No Yes No

C56.38 x 11.77 in162 x 229 mm

No Yes No

DL4.33 x 8.66 in110 x 220 mm

No Yes No

2000-Sheet Input Drawer Paper Specifications


(SEF)Long-edge feed

(LEF)

Letter8.5 x 11 in215.9 x 279.4 mm

Yes No Yes

A48.27 x 11.69 in210 x 297 mm

Yes No Yes


Appendix D. Technical SupportIBM Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602Technical Support Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602Obtaining Documents, Drivers, and Utilities from the World Wide Web . . . . . . . . . . . . . . . . . . . .603Obtaining Code Updates from the World Wide Web. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603Dealer Warranty Claim Center (DWCC)—U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603Printer Sales Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603

IBM Warranty InformationWarranty period: 12 months

Warranty offerings: On-site:v Dealerv IBM service

Technical Support NumbersIBM customer support for this printer is available at no charge when covered by an IBM maintenanceagreement or the IBM one-year warranty period. If the printer requires repair, the support representative willexplain the customer’s options.v U.S.A. and Canada: 1-800-358-6661.v Outside the U.S.A. and Canada, customers should call their country customer service center numbers.


Obtaining Documents, Drivers, and Utilities from theWorld Wide WebTo obtain current versions of the InfoPrint 20 documentation, printer drivers, utilities, and programs, thecustomer can do the following:1. Access the IBM Printing Systems Company home page:

http://www.printers.ibm.com

2. Navigate to the document, printer driver, utility, or program needed and follow the instructions to downloadit.

Obtaining Code Updates from the World Wide WebTo obtain code updates for the InfoPrint 20, if required, the customer can do the following:1. Access the IBM Printing Systems Company home page:

http://www.printers.ibm.com

2. Navigate to the code update needed and follow the instructions to download it.

Dealer Warranty Claim Center (DWCC)—U.S.A. onlyTo order warranty parts and request warranty claim reimbursements through the Dealer Warranty ClaimsCenter, call: 1-800-388-7080

Printer Sales InformationIBM Printer Remarketer: 1-800-793-5888 (U.S.A.) or IBM country remarketer.

Appendix D. Technical Support 603

Appendix E. Duplex Unit OptionDiagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607

09 DUPLEX COVER OPEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60722 PAPER JAM (or 21 PAPER JAM from Duplex). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60829 OUTPUT FULL, with Duplex Installed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .610

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614Removal Procedures, Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615

Duplex Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616

Duplex Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618

Duplex Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620

Duplex Upper Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .621Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622

Duplex Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .623Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .623Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624

Offset Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626

Duplex PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .628


Duplex Cover Switch1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .630

Duplex Cover Switch2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .632

Duplex Pass Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .633Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .633Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .634

Duplex Stack Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636

Duplex Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .638

Offset Guide Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640

Offset Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643

Duplex Upper Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .646

Duplex Lower Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649

Duplex Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651

Appendix E. Duplex Unit Option 605

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652Assembly 30: Duplex Unit and Offset Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652Assembly 31: Duplex Unit and Offset Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655


DiagnosticsIf the problem involves only duplex printing, install a new duplex unit.

09 DUPLEX COVER OPENOne of the duplex covers is open. Ensure that both covers are closed correctly. Also ensure that the option isinstalled correctly and plugged tightly to the connector on the Duplex Interface PWB.Table 81. 09 DUPLEX COVER OPEN


SUSPECT COMPONENTS

v Duplex Option (Asm-Index: 30-1, page 652)

v Duplex Interface PWB (Asm-Index: 12-6, page 575)

v MCU


22 PAPER JAM (or 21 PAPER JAM from Duplex)There was a paper jam at the duplex option.Table 82. 22 PAPER JAM


SUSPECT COMPONENTS

v Duplex Option (Asm-Index: 30-1, page 652)

1.

DUPLEX OPTION

Check for dirty rolls, obstructions, broken actuators, etc.


Verify the fix. Alsoverify that theproblem job prints.

Go to step 2

2.

DUPLEX OPTION

Install a new Duplex Option (see page “Duplex Unit” on page 615).Note: The following diagnostics are available:

v Sensors – “D21 SENSOR TEST” on page 261

v Duplex Motor – “D63 MOTOR D CW (Duplex Motor Runs CW)” onpage 287 and “D64 MOTOR D CCW (Duplex Motor Runs CCW)” onpage 289



Go to “SkewedImage” onpage 212




3.




If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do notfind a solution, call your next level of support (see “Appendix D. Technical Support” on page 602).


29 OUTPUT FULL, with Duplex InstalledWithout a duplex option, the printer monitors the output full condition at the Full Stack Actuator (Asm-Index:8-8, page 564) within the Fuser Assembly. When a duplex option is installed, the printer monitors the DuplexStack Actuator (Asm-Index: 30-18, page 652) and ignores the signals from the base Full Stack Actuator.

When a full stack condition is detected for 4 consecutive pages, a 29 OUTPUT FULL message is displayed onthe operator panel. The printer will continue to print a few more pages to clear the paper path before it stops.The 29 OUTPUT FULL message remains until the signals indicate that the the paper stack has beenremoved.

Notes:

1. This error code is not displayed until the Full Stack Sensor has been activated for 4 pages. The printer willstop after the paper path clears.

2. If false 29 OUTPUT FULL messages occur with a duplex unit installed, the customer can probably removethe duplex unit and continue to print simplex jobs.

Table 83. 29 OUTPUT FULL, with Duplex Installed


SUSPECT COMPONENTS

v Duplex Full Stack Actuator (Asm-Index: 30-18, page 652)

v Duplex Unit (Asm-Index: 30-1, page 652)

v Duplex Interface PWB (Asm-Index: 12-6, page 575)



Table 83. 29 OUTPUT FULL, with Duplex Installed (continued)


1.

SENSOR TESTa. Use “D21 SENSOR TEST” on page 261 to check the Duplex Full

Stack Actuator and Sensor.

b. Press and release the actuator.

Is the sensor OK?

Possibleintermittent orMCU problem

Go to step 2

2.

DUPLEX STACK ACTUATORa. Unplug the duplex option from the back of the printer.b. Carefully remove the option from the printer.c. Place the option on a table.d. Manually actuate the Duplex Stack Acutator and observe the Duplex

Stack Sensor at the other end of the actuator. Look for debris thatcould obstruct the actuator or sensor.

Are the actuator and sensor OK?

Go to step 3 Repair as neededor install a newDuplex Unit.

3.

DUPLEX UNIT INSTALLATIONa. Carefully install the duplex option on the printer. Tighten the

thumbscrews.b. Plug the duplex option into the printer connection and tighten the

thumbscrews.c. Run TEST MENU/CONTINUOUS TEST for about 10 pages. Then

press the CANCEL key (the printer will print many more pages beforestopping).

Does the 29 OUTPUT FULL message display?

Go to Step 4Problem appearsfixed. Verify thefix. Also verify thatthe problem jobprints.




4.

DUPLEX UNITa. Install a new (or borrowed) duplex unit.

Note: The printer can probably continue to be used without the duplexunit if a new duplex unit is needed but not immediately available.

b. Repeat the D21 test

Is the sensor OK?

The originalduplex unit wasbad.

Go to Step 5

5.

FULL STACK SENSING WITHOUT THE DUPLEX UNITa. Remove the duplex unit.b. Repeat D21, activating the base Full Stack Actuator (at the fuser asm).

Is the sensor OK?

Go to Step 6 The onlycomponent sharedby the Full Stacksensor and theDuplex Full StackSensor circuits isthe MCU. Install anew MCU.

6.

Install a new Duplex Interface PWB (See page 615).

Ensure that the connection at the MCU is completely seated- it can lookconnected when it is not.



Install a new MCU




7.




If the printer still fails, return to “Diagnostic Quick Path” on page 28 and define the problem again. If you do notfind a solution, call your next level of support (see “Appendix D. Technical Support” on page 602).


Wiring Diagram

HC2M815F

DUPLEX INTERFACE PWB

DUPLEX PWB

MCU

P/J192

P/J193

P/J198

P/J184

P/J186 P/J187

P/J18

P/J20

P182

P183

DUP STACKSENSOR

OFFSETMOTOR

DUPLEX PASSSENSOR

DUPLEXMOTOR

DUP COVERSWITCH 1

DUP COVERSWITCH 2

P/J196 P/J197 P/J195

MM


Removal Procedures, Adjustments

Duplex UnitAsm-Index: 30-1, page 652.

J182 hc2m758F

21

3

3

Figure 82. Duplex Unit Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Disconnect J182 of the duplex cable (Asm-Index: 30-23, page 652) from the rear of the base engine.

3. Remove the paper weight (1) (Asm-Index: 30-30, page 652) from the duplex front cover (2) (Asm-Index:30-7, page 652).

4. Loosen the two knurled screws (3) on the back side of the duplex unit.5. Lift the duplex unit up back and remove it from the base engine.6. Lay the duplex unit on a flat surface holding inside up.

Replacement

Reverse the Removal procedure.


Duplex Left CoverAsm-Index: 30-3, page 652.

J182hc2m759F

3

3

2 1

5

4

Figure 83. Duplex Left Cover Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex unit (See page 615).

3. Remove the E-ring (1) holding the left side knurled screw (2).4. Loosen (do not remove) the two screws (3) securing the duplex left cover (4).5. Place the duplex unit on a flat surface left side up.6. Tilt the duplex left cover backward and loosen the hook (5) of the left cover from the frame of the duplex

unit.7. Remove the cable from the slot in the left end cover.8. Lift the left cover and remove it from the duplex unit.9. Lay the duplex unit on a flat surface inner side up.

Replacement



Duplex Right CoverAsm-Index: 30-4, page 652.


hc2m760F

1

3

24

5

3

Figure 84. Duplex Right Cover Removal


3. Remove the E-ring (1) holding the right side knurled screw (2).4. Loosen (do not remove) the two screws (3) securing the duplex right cover (4).5. Place the duplex unit right side up.6. Open the duplex lower cover (Asm-Index: 30-6, page 652).

7. Tilt the duplex right cover backward and loosen the hook (5) of the right cover from the frame of theduplex unit.

8. Lift the right cover and remove it from the duplex unit.9. Close the lower cover.

10. Lay the duplex unit on a flat surface inside up.

Replacement



Duplex Upper CoverAsm-Index: 30-5, page 652.

hc2m761

1

2

Figure 85. Duplex Upper Cover Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Hold the duplex upper cover (1) half open.3. Remove the duplex straps (2) (Asm-Index: 30-22, page 652) from the duplex unit (Asm-Index: 30-1, page

652).

4. Slide the upper cover to the left up, and release the right side hinge boss from the frame of the duplex unitpressing the arm inside using a flat blade screwdriver, if necessary.

5. Remove the left side hinge boss from the frame.

Replacement



Duplex Lower CoverAsm-Index: 30-6, page 652.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Hold the duplex lower cover (1) half open.3. Slide the lower cover to the left up, then remove the right side hinge boss from the frame of the duplex

unit (Asm-Index: 30-1, page 652) pressing the arm inside using a flat blade screwdriver, if necessary.

hc2m762F

1

Figure 86. Duplex Lower Cover Removal


4. Remove the left side hinge boss from the frame.

Replacement



Offset MotorAsm-Index: 30-21, page 652.

J186

hc2m764F

1

2

Figure 87. Offset Motor Removal



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



Duplex PWBAsm-Index: 30-10, page 652.



J182

J183

J187J184

hc2m765F

1

2

2

2

Figure 88. Duplex PWB Removal


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



Duplex Cover Switch1Asm-Index: 30-11, page 652.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Open the duplex upper cover (Asm-Index: 30-5, page 652).

J193

hc2m766F

1

Figure 89. Duplex Cover Switch1 Removal


3. Nip the duplex cover switch 1 (1) in a vertical direction and remove it from the frame of the duplex unit(Asm-Index: 30-1, page 652).

Attention: Be careful not to damage the duplex sensor harness (Asm-Index: 30-15, page 652).

4. Disconnect J193 of the duplex sensor harness from the switch.

Replacement1. Open the duplex upper cover.2. Reconnect J193 of the duplex sensor harness to the duplex cover switch1.3. Push the switch into the opening in the frame until the switch snaps in place.4. Route the wires of the harness inside the frame of the duplex unit.5. Close the duplex upper cover.

Note: Ensure that the tab on the duplex upper cover presses the switch.


Duplex Cover Switch2Asm-Index: 30-12, page 652.


3. Disconnect J198 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex cover switch2 (1).

4. Remove the duplex lower cover (See page 623).

J198

hc2m767F

1

Figure 90. Duplex Cover Switch2 Removal


5. Nip the duplex cover switch2 in a vertical direction from the back side of the duplex unit (Asm-Index: 30-1,page 652), using a needle nosed pliers if necessary, and pull the switch out from the frame of the duplexunit.

Replacement1. Lay the duplex unit back side up.2. Push the duplex switch2 into the opening in the frame of the duplex unit until the switch snaps in place.3. Reconnect J198 of the duplex sensor harness to the switch.4. Route the wires of the harness inside of the frame of the duplex unit.5. Reinstall the duplex lower cover (See page 623).

6. Close the duplex lower cover (Asm-Index: 30-6, page 652).

Note: Ensure that the tab of the duplex lower cover presses the duplex cover switch2.

7. Reinstall the duplex unit (See page 615).


Duplex Pass SensorAsm-Index: 30-13, page 652.


3. Disconnect J195 from the duplex pass sensor (1).4. Nip the hooks of the sensor and remove it from the frame of the duplex unit (Asm-Index: 30-1, page 652).

J195

hc2m768F

1

Figure 91. Duplex Pass Sensor Removal


Replacement1. Lay the duplex unit inside up.2. Push the duplex pass sensor into the hole in the frame until the sensor snaps in place.3. Reconnect J195 to the sensor.

Note: Ensure that the harness wires are in the hanger.4. Reinstall the duplex unit (See page 615).


Duplex Stack SensorAsm-Index: 30-17, page 652.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the duplex upper cover (See page 621).

3. Remove the duplex unit (See page 615).


5. Remove the duplex right cover (See page 619).

6. Remove the duplex front cover.7. Lay the duplex unit (Asm-Index: 30-1, page 652) inside up on a pillow so that the actuator of the duplex

pass sensor (Asm-Index: 30-13, page 652) does not touch the floor.

J192

hc2m769F

1

Figure 92. Duplex Stack Sensor Removal


8. Disconnect J192 of the duplex sensor harness (Asm-Index: 30-15, page 652) from the duplex stack sensor(1).

9. Nip the hooks of the stack sensor and remove it from the duplex eliminator assembly (Asm-Index: 30-16,page 652).

Replacement1. Lay the duplex unit inside up on a pillow so that the actuator of the duplex pass sensor does not touch the

floor.2. Push the duplex stack sensor into the opening until the sensor snaps in place.3. Reconnect J192 of the duplex sensor harness to the sensor.4. Route the wires of harness into the frame of the duplex unit.5. Reinstall the duplex front cover.6. Reinstall the duplex right cover (See page 619).

7. Reinstall the duplex left cover (See page 617).

8. Reinstall the duplex unit (See page 615).

9. Reinstall the duplex upper cover (See page 621).


Duplex Stack ActuatorAsm-Index: 30-18, page 652.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove duplex unit (See page 615).

3. Lay the duplex unit inside up.4. Nip the center of the bar of the duplex stack actuator (1) using a needle nosed pliers and pull the bar to

flex it.5. Remove the right end of the bar (opposite side of the duplex stack sensor) (Asm-Index: 30-17, page 652)

from the hole on the frame of the duplex eliminator assembly (Asm-Index: 30-16, page 652).

hc2m770F

1

Figure 93. Duplex Stack Actuator Removal


6. Turn the lever of the actuator up so that the shielding flag of the actuator leaves from the stack sensor.7. Slide the actuator to the right and remove the bar from the hole of the duplex eliminator.

Replacement



Offset Guide ArmAsm-Index: 30-20, page 652.

Note: This procedure is applicable only to the models with the offset Function.

hc2m772F

1 2

Figure 94. Offset Guide Arm Removal



3. Remove duplex unit (See page 615).

4. Remove duplex left cover (See page 617).

5. Lay the duplex unit inside up on a pillow so that the duplex pass sensor (Asm-Index: 30-13, page 652)does not touch the floor.

6. Tilt the lever of the offset motor (Asm-Index: 30-21, page 652) toward the outside of the duplex unit.

7. Remove the screw (1) securing the offset guide arm (2).8. Slide the offset guide arm slightly toward the front so that it leaves the lever of the offset motor and

remove the arm from the frame.

Replacement



Offset AssemblyAsm-Index: 31-6, page 655.


hc2m773F

1

12

Figure 95. Offset Assembly Removal (1)


3. Remove the duplex unit (See page 615).



Note: Step 6 is applicable only to the models without the offset function.

6. Remove the offset hold arm.

Note: Step 7 is applicable only to the models with the offset function.7. Remove the offset guide arm (See page 639).

8. Lay the duplex unit top side down.9. Remove the two screws (1) securing the duplex support assembly (2) (Asm-Index: 31-4, page 655).

10. Remove the duplex support assembly together with the duplex guide (Asm-Index: 30-8, page 652).

11. Slide the offset assembly (3) right and left and remove the four bearings (4) from the frame of the duplexunit.

12. Lift the right end of the offset assembly in the direction of the cutout in the frame and release the twoshafts from the frame of the duplex unit.

13. Slide the offset assembly to the right and remove it with the four duplex bearings (Asm-Index: 31-10,page 655) and two offset gears (5) (Asm-Index: 31-22, page 655) from the frame.


Replacement1. Lay the duplex unit top side down.2. Turn the duplex stack actuator so that the tip of the lever directs to the top of the duplex unit.3. Hold the shafts of the offset assembly with the gear side to the right.4. Set two duplex bearings and the offset gear to each shaft in the order below from left side of the shaft.v duplex bearing - (collar right)v duplex bearing - (collar left)v offset gear - (collar left)

5. Insert the left ends of the shafts of the offset assembly into the openings in the frame of the duplex unit.6. Insert the right side of the shafts of the offset assembly placing the four bearings inside and two gears

outside of the frame making sure that the gear collars are on the inside of the large gear (See Figure 99on page 650).

hc2m774F

4

4

3

5

4

Figure 96. Offset Assembly Removal (2)


7. Slide the body of the left side bearings and insert them into the openings in the frame until the collarstouch the frame.

8. Place the left side of the duplex support assembly so that its left end fixes the left side bearings.9. Slide the body of the right side bearings and insert them into the openings in the frame until the collars

touch the frame.10. Place the right side of the duplex support assembly.11. Secure the duplex support assembly using two screws (silver, 6mm).

Note: Step 12 is applicable only to the models without the offset function.12. Reinstall the offset hold arm.

Note: Step 13 is applicable only to the models with the offset function.13. Reinstall the offset guide arm (See page 639).

14. Reinstall the duplex right cover (See page 619).


16. Reinstall the duplex chute (See page 615).

17. Reinstall the duplex upper cover (See page 621).


Duplex Upper RollAsm-Index: 31-11, page 655.




5. Lay the duplex unit inside up.6. Disconnect P/J195 from the duplex pass sensor (Asm-Index: 30-13, page 652).

7. Release the harness from the harness collar (Asm-Index: 31-24, page 655).

hc2m775F

J195

Figure 97. Duplex Upper Roll Removal


8. Remove the harness collar from the duplex upper roll.9. Remove the left side clamp securing the duplex upper roll.

10. Remove the synchronize belt (Asm-Index: 31-16, page 655).

11. Remove the left side duplex collar (Asm-Index: 31-15, page 655).

12. Remove the pulley gear (Asm-Index: 31-14, page 655).

13. Remove the duplex gear ’D’ (Asm-Index: 31-18, page 655).

14. Remove the right side duplex collar and the duplex bearing (Asm-Index: 31-13, page 655).

15. Slide the duplex upper roll to the right and release the right side duplex bearing from the frame of theduplex unit.

16. Lift the right end of the duplex upper roll and remove its right end from the frame.17. Slide the upper roll to the right and pull out its left end from the frame.18. Release the hooks and the E-clip of the one way gear (Asm-Index: 31-17, page 655) using a small flat

blade screwdriver and remove the gear and the bearing from the shaft.

Replacement1. Lay the duplex unit inside up.2. Hold the shaft of the duplex upper roll with the gear side left.3. Insert the left end of the shaft of the upper roll into the opening in the frame of the duplex unit.4. Place right end of the shaft of the upper roll into the cutout in the frame.5. Place the duplex bearing (collar right) to the shaft from the outside of the frame.6. Insert the body of the right side duplex bearing into the opening of the frame.7. Place the one way gear from the right side end of the duplex upper roll until the gear snaps into place.8. Slide the upper roll to the left.9. Place the duplex bearing, the duplex collars and the pulley gear on the shaft of the upper roll from the

left side of the frame, in the order below.


v duplex bearing (collar left)v duplex collarv pulley gearv duplex collar

10. Secure the collars, etc. to the upper roll using a clamp.11. Reinstall the synchronize belt.12. Reinstall the harness collar to the duplex upper roll.13. Hook the harness of the duplex pass sensor to the harness collar.14. Reconnect P/J195 to the duplex pass sensor.15. Reinstall the duplex right cover (See page 619).



Duplex Lower RollAsm-Index: 31-12, page 655.




5. Lay the duplex unit inside up.6. Remove the left side clamp securing the duplex lower roll.

hc2m776F

Figure 98. Duplex Lower Roll Removal


7. Remove the synchronize belt (Asm-Index: 31-16, page 655).

8. Remove the left side duplex collar (Asm-Index: 31-15, page 655), the pulley gear (Asm-Index: 31-14,page 655), and the right side duplex bearing (Asm-Index: 31-13, page 655).

9. Slide the duplex lower roll to the right and release the right side duplex bearing from the frame.10. Lift the right end of the lower roll and remove its right end from the frame.11. Slide the lower roll to the right and pull out its left end from the frame.12. Release the E-ring and remove the duplex bearing from the right end of the shaft.

Replacement1. Lay the duplex unit inside up.2. Hold the shaft of the duplex lower roll with the pulley gear side left.3. Insert the left end of the shaft of the lower roll into the opening in the frame of the duplex unit.4. Insert the duplex bearing (collar right) to the shaft of the lower roll from the right end.5. Secure the bearing using an E-ring.6. Place the right end of the shaft of the lower roll placing the duplex bearing outside of the frame.7. Place the left side duplex bearing, the duplex collars and the pulley gear on the lower roll from the

outside of the frame, in the order below.v duplex bearing (collar left)v duplex collarv pulley gearv duplex collar

8. Secure the duplex collar, etc. to the lower roll using a clamp.9. Reinstall the synchronize belt.

10. Reinstall the duplex right cover (See page 619).



Duplex MotorAsm-Index: 31-23, page 655.

J197 hc2m777F

1

2

2

Figure 99. Duplex Motor Removal




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



Parts Catalog

Assembly 30: Duplex Unit and Offset Feeder I

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m755F


Table 84. Assembly 30: Duplex Unit and Offset Feeder I

Asm–Index Grid


30– Duplex unit and offset feeder I

–1 A4 90H0716 1 Duplex unit (with 30-2∼30-30)

–2 B3 90H0716 1 v Duplex paper handling assembly (same as 31-1)

–3 A1 90H3359 1 v Duplex left cover

–4 B4 90H3360 1 v Duplex right cover

–5 A4 90H3361 1 v Duplex upper cover

–6 C3 90H3362 1 v Duplex lower cover

–7 A2 NP 1 v Duplex front cover

–8 C2, C3 NP 2 v Duplex guide

–9 C3 NP 1 v Duplex gate spring

–10 B1 90H3363 1 v Duplex PWB

–11 B2 90H3364 1 v Duplex cover switch 1

–12 C2 90H3365 1 v Duplex cover switch 2

–13 C2 90H3366 1 v Duplex pass sensor

–14 C1 90H3367 1 v Duplex motor harness

–15 B1 90H3368 1 v Duplex sensor harness

–16 B2 NP 1 v Duplex eliminator assembly

–17 B2 63H3079 1 v Duplex stack sensor

–18 B2 90H3370 1 v Duplex stack actuator

–19 B1 NP 1 v Offset hold arm


Table 84. Assembly 30: Duplex Unit and Offset Feeder I (continued)

Asm–Index Grid


30– Duplex unit and offset feeder I

–20 B1 90H3371 1 v Offset guide arm

–21 B1 90H3372 1 v Offset motor

–22 A3 90H3373 1 v Duplex strap

–23 C1 90H3374 1 v Duplex cable

–30 A2 90H3375 1 v Paper weight



Assembly 31: Duplex Unit and Offset Feeder II

hc2m756F

1 2 3 4

1 2 3 4

A

B

C

A

B

C

25

25

25

2


Table 85. Assembly 31: Duplex Unit and Offset Feeder II

Asm–Index Grid


31– Duplex unit and offset feeder II

–1 A3 90H0716 1 Duplex paper handling assembly (with 31-2∼ 31-24 (same as 30-2)

–2 C2 NP 1 v Duplex frame L

–3 C3 NP 1 v Duplex frame R

–4 B2 NP 1 v Duplex support assembly

–5 B3 NP 1 v Duplex chute

–6 A2 90H3376 1 v Offset assembly (with 31-7∼31-10)

–7 A3 1 v Offset chute assembly

–8 A2 1 v Offset roll

–9 A2 1 v v Offset/Exit roll

–10 A2, A3 4 v v Duplex bearing (in kit P/N 11L5321) (see page 580)

–11 C2 90H3377 1 v v Duplex upper roll

–12 C2 07L0043 v v Duplex lower roll

–13 A1, A2,A3, B1,C1, C4

8 v Duplex bearing (in kit P/N 11L5321) (see page 580)

–14 B1, B2 2 v Pulley gear (in kit P/N 11L5321) (see page 580)

–15 B1, C1 2 v Duplex gear (in kit P/N 11L5321) (see page 580)

–16 B1 90H3378 1 v Sync belt

–17 C4 1 v One-way gear (in kit P/N 06L9998) (see page 580)

–18 C4 1 v Duplex gear D (in kit P/N 06L9998) (see page 580)


Table 85. Assembly 31: Duplex Unit and Offset Feeder II (continued)

Asm–Index Grid


31– Duplex unit and offset feeder II

–19 C4 1 v Duplex gear C (in kit P/N 06L9998) (see page 580)

–20 B4 3 v Duplex gear B (in kit P/N 06L9998) (see page 580)

–21 B4 1 v Duplex gear A (in kit P/N 06L9998) (see page 580)

–22 A3, A4 2 v Offset gear (in kit P/N 06L9998) (see page 580)

–23 B4 90H3379 1 v Duplex motor

–24 B2 NP 1 v Return chute assembly

–25 C1, C2 NP ? v Clip


Appendix F. Envelope Tray OptionParts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .659


Parts Catalog

1 2 3 4

1 2 3 4

A

B

C

A

B

C

1

25

hc2m509F

Appendix F. Envelope Tray Option 659

Table 86. Assembly 24: Envelope Tray Option

Asm–Index Grid


24– Envelope Tray Option

–1 A3 90H0721 1 Envelope Tray Option with Cover

–25 C2 90H3467 1 A4 Cassette Cover


Appendix F. Envelope Tray Option 660

Appendix G. 500-Sheet Paper Tray OptionDiagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .663

11 LOAD <size> IN TRAY n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66316 TRAY n MISSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66317 TRAY n OPTION ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66421 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .664


Feeder Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .666Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .667

Feed Housing Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .669

Feed Housing Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .671

Feeder Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .672Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .673Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .673

Feeder PWB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .674Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .675

Turn In Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .676Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677

Turn Chute Assembly Aux.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678


Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .679Cassette Guide Assembly L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .680

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681

Cassette No Paper Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684

Cassette Guide Assembly R . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .686

Cassette No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .687Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .687Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688

Feed Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690

Feed Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .691Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .691Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .692

Electromagnetic Clutch Aux. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .694

Turn Roll Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .696

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697Assembly 20: Optional Tray 2/3 Feeder I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .697Assembly 21: Optional Tray 2/3 Feeder II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700

Appendix G. 500-Sheet Paper Tray Option 662

Diagnostics

11 LOAD <size> IN TRAY nUse this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.Table 87. 11 LOAD <size> IN TRAY n


SUSPECT COMPONENTS

v Connection to the tray above the optionv 500 Sheet Feeder (Asm-Index: 20-1, page 697)

v If failing option is in the Tray 2 position: Tray 1 Feeder PWB(Asm-Index: 3-1, page 553)

16 TRAY n MISSINGMeaning : Paper Cassette (Tray 1), Tray 2 and/or Tray 3 are not in place.

Action : Open and close the tray. If you have not installed the tray, do so at this time.Table 88. 16 TRAY n MISSING


SUSPECT COMPONENTS




17 TRAY n OPTION ERRORA 500-sheet option is installed, but is not detected. Ensure that the option is installed correctly.Table 89. 17 TRAY n OPTION ERROR


SUSPECT COMPONENTS



21 PAPER JAMUse this diagnostic only if you have ensured that printing from Tray 1 and the Auxiliary Tray is OK.Table 90. 21 PAPER JAM


SUSPECT COMPONENTS




Wiring Diagram

HC2M858F

MCU

P/J18

P/J20

FEEDER PWB

FEEDER PWB

FEEDER PWB

P202

P202

P202

P207

P207

P207

P201

P201

P201

FEEDSOLENOID

FEEDSOLENOID

CASSETTENO PAPERSENSOR

CASSETTENO PAPERSENSOR

TURNCLUTCH

TURNCLUTCH

P/J203

P/J203

P/J904

P/J904

P/J205

P/J205

P/J906

P/J906

P/J204

P/J204

P/J206

P/J206



Feeder AssemblyAsm-Index: 20-1, page 697.

1

hc2m707F

2

2

Figure 100. Feeder Assembly Removal


Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the base engine and the feeder assembly.

3. Remove the two screws (1), using a stabilizer screwdriver, securing the feeder assembly to the baseengine.

4. Lift the base engine to separate it from the feeder assembly.

Replacement1. Rotate the feed roll (Asm-Index: 21-11, page 700) until its rubber surface faces up.

2. Lift the base engine and place it on the feeder assembly positioning the holes in the base engine to thebosses (2) on the feeder assembly.

Attention: Move the base engine horizontally and slowly.3. Using a stabilizer screwdriver, secure the base engine to the feeder assembly using the two screws.


Feed Housing LeftAsm-Index: 20-3, page 697.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the paper cassette (Asm: 2, page 550) from the feeder assembly (Asm-Index: 20-1, page 697).

3. Remove the screw (1) securing the feed housing left (2) to the cassette guide assembly left (Asm-Index:20-16, page 697).

4. Remove the four screws (3) securing the feed housing to the feeder assembly.5. Remove the housing.

hc2m708F

1

2

33

Figure 101. Feed Housing Left Removal


Replacement



Feed Housing RightAsm-Index: 20-4, page 697.


3. Remove the screw (1) securing the feed housing right to the cassette guide assembly right (2) (Asm-Index:20-23, page 697).

hc2m709F

1

2

3 3

Figure 102. Feed Housing R Removal


4. Remove the four screws (3) securing the feed housing to the feeder assembly.5. Remove the feed housing.

Replacement



Feeder Front CoverAsm-Index: 20-5, page 697.

hc2m710F

2 3

3

1

Figure 103. Feeder Front Cover Removal


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



Feeder PWBAsm-Index: 20-11, page 697.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing left (See page 668).

3. Disconnect J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB.

J201

J202

J203

hc2m711F

2

1

1

Figure 104. Feeder PWB Removal


Attention: Do not move the feeder PWB away from the feeder assembly (Asm-Index: 20-1, page 697). Theyare still connected by harnesses.

4. Remove the four screws (1) securing the feeder PWB (2) to the feeder assembly.5. Disconnect J201 of the tray upper harness (Asm-Index: 20-27, page 697) and /J202 of the tray lower 2

harness (Asm-Index: 20-12, page 697) from the feeder PWB.

6. Remove feeder PWB from the feeder assembly.

Replacement1. Reconnect J201 of the tray upper harness and J202 of the tray lower 2 harness to the feeder PWB.

Attention: Do not damage the paper size switch on the feeder PWB during step 2.2. Place the feeder PWB on the feeder assembly.3. Secure the feeder PWB to the feeder assembly using four screws (silver, 6mm).4. Reconnect J203 of the feeder harness to the feeder PWB.5. Route the harnesses so as not to interfere with the function of the paper Size switch.6. Reinstall the feed housing left (See page 668).


Turn In ChuteAsm-Index: 20-14, page 697.


3. Open the turn chute assembly aux (1). (Asm-Index: 20-15, page 697).

4. Flex the left side arm of the turn in chute (2) and remove its hinge hole from the boss on the cassetteguide assembly left (Asm-Index: 20-16, page 697).

5. Remove the turn in chute from the cassette guide assembly right (Asm-Index: 20-23, page 697).

hc2m712F

2

1

Figure 105. Turn In Chute Removal


Replacement



Turn Chute Assembly Aux.Asm-Index: 20-15, page 697.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the turn in chute (See page 676).

3. Hold the chute assembly open and slide it to the left.4. Lift the rear of the feeder assembly (Asm-Index: 20-1, page 697) and pull the right side of the turn chute

down.

5. Slide the chute to the right and remove it from the feeder assembly.6. Lower the feeder assembly.

hc2m713F1

Figure 106. Turn Chute Assembly Aux. Removal


Replacement



Cassette Guide Assembly LAsm-Index: 20-16, page 697.

J203

J206

J204

hc2m714F

2

3

1

1

2

4

Figure 107. Cassette Guide Assembly Left Removal




4. Remove the turn chute assembly aux. (See page 678).

5. Disconnect:v J203 of the feeder harness (Asm-Index: 20-22, page 697) from the feeder PWB (Asm-Index: 20-11,

page 697)

v J204 from the feed solenoid (Asm-Index: 21-18, page 700)

v J206 of the feeder harness connecting to the electromagnetic clutch aux. (Asm-Index: 21-19, page700)

6. Release the clutch side of the feeder harness from the clamp.7. Release the three screws (1) securing the cassette guide assembly L (2) from outside of the frame.8. Remove the screw (3) securing the cassette guide from the front bottom inside the cassette well.9. Using a flat blade screwdriver, push the three hooks (4) at the bottom of the cassette guide assembly L,

up and in, one by one, to release them from the frame.10. Tilt the cassette guide, pulling its bottom edge from the inside of the cassette well.11. Ensure that the three upper hooks of the cassette guide are released from the frame.12. Ensure that the upper part of the cassette guide does not touch the cassette no paper actuator

(Asm-Index: 20-26, page 697)

13. Push all harnesses on the cassette guide to free them from the frame.14. Remove the cassette guide from the feeder assembly.

Replacement1. Hold the cassette guide assembly left with the bottom to the right and top to the left so that it will not

interfere with the cassette no paper actuator.


2. Insert the cassette guide into the paper cassette well.3. Insert all connectors on the cassette guide through their openings in the frame.4. Place the upper three hooks of the cassette guide in their respective holes in the frame.5. Pull the feeder harness through the opening in the frame to keep them from being pinched between the

cassette guide and the frame.6. Press the bottom of the cassette guide, tilting it up until the upper and lower hooks lock into position.7. Secure the cassette guide to the feeder assembly using three screws (gold, self tapping, 8mm).8. Insert harnesses to clamps.9. Reconnect:v J203 of the feeder harness to the feeder PWBv J204 to the feed solenoidv J906 of the feeder harness connecting to the electromagnetic clutch aux.

Attention: Route the harnesses so as not to interfere with the gears.10. Ensure the cassette no paper actuator functions properly.11. Reinstall the turn chute assembly aux. (See page 678).

12. Reinstall the turn in chute (See page 676).

13. Reinstall the feed housing left (See page 668).


Cassette No Paper SensorAsm-Index: 20-21, page 697.



J205

hc2m715F

2

1

Figure 108. Cassette No Paper Sensor Removal


4. Swing the armature (1) of the cassette no paper actuator (Asm-Index: 20-26, page 697) to the rear so thatthe actuator is away from the cassette no paper sensor (2).

5. Open the turn in chute (Asm-Index: 20-14, page 697).

6. Use a small flat blade screwdriver to release the hooks of the no paper sensor, located at the inside of thefeeder assembly (Asm-Index: 20-1, page 697) (work from the rear of the frame), from the feeder assembly.

Attention: Do not move the cassette no paper sensor away since it is connected with a harness.

7. Disconnect J205 from the sensor.8. Remove the sensor.

Replacement1. Swing the arm of the cassette no paper actuator to the rear so that the actuator is away from the cassette

no paper sensor.2. Reconnect J205 to the no paper sensor.3. Position the sensor in the opening in the frame, and press the sensor into place until the hooks of the

sensor snap into position.4. Tack the extra length of the harness into the wiring channel of the cassette guide so that the harness does

not interfere with the gears.5. Reinstall the turn in chute (See page 676).



Cassette Guide Assembly RAsm-Index: 20-23, page 697.

Removal1. Switch off printer power and unplug the power cord from the wall.2. Remove the feed housing right (See page 670).



hc2m716F

2

2

1

13

3

Figure 109. Cassette Guide Assembly R Removal


5. Remove the three screws (1) securing the cassette guide assembly R (2) to the feeder assembly(Asm-Index: 20-1, page 697).

6. Using a flat blade screwdriver, push the three hooks (3) at the bottom of the cassette guide assembly R,up and in, one by one, to release them from the frame of the feeder assembly.

7. Tilt the cassette guide, pulling its bottom edge from the inside of the frame.8. Ensure that the three upper hooks of the cassette guide are released from the frame.9. Remove the cassette guide from the feeder assembly.

Replacement



Cassette No Paper ActuatorAsm-Index: 20-26, page 697.




5. Remove the cassette guide assembly left (See page 680).

hc3u717F

1

Figure 110. Cassette No Paper Actuator Removal


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



Feed RollAsm-Index: 21-11, page 700.




hc2m718F

4

5

5

4

1

32

Figure 111. Feed Roll Removal


5. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15,page 700) and the frame.

6. Remove the E-ring (3) securing the feed core (Asm-Index: 21-13, page 700) to the feed shaft assembly(4) (Asm-Index: 21-12, page 700).

7. Remove the feed core, the feed core spring (Asm-Index: 21-14, page 700), and the feed gear from thefeed shaft assembly.

8. Rotate the feed shaft assembly until the rubber surface of the feed roll (5) faces to the front.


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).




Feed SolenoidAsm-Index: 21-18, page 700.


J204 hc2m720F

1

3

4

2

Figure 112. Feed Solenoid Removal


3. Remove the feed spring (1) (Asm-Index: 21-17, page 700) from the feed gear (2) (Asm-Index: 21-15, page700) and the frame.

4. Disconnect J204 of the feed solenoid (3) from the feeder harness (Asm-Index: 20-22, page 697) on thecassette guide assembly L (Asm-Index: 20-16, page 697).

5. Remove the screw (4) securing the feed solenoid to the cassette guide assembly.6. Remove the solenoid from the cassette guide.

Replacement1. Place the feed solenoid in position and secure it using a screw (silver, 6mm).2. Reconnect J204 of the feed solenoid to the feeder harness on the cassette guide assembly L.Attention: Route the harness so that it does not touch the gears.3. Reinstall the feed spring between the feed gear and the feed solenoid.4. Ensure that the armature of the feed solenoid fixes the feed gear at the upper position, and releases at the

lower position.5. Rotate the feed shaft to place the rubber surface of the feed roll (Asm-Index: 21-11, page 700) up until the

feed gear is released from the feed idler gear (Asm-Index: 21-22, page 700).



Electromagnetic Clutch Aux.Asm-Index: 21-19, page 700.




J206

hc2m721F

1

2

3

2

4

5

Figure 113. Electromagnetic Clutch Aux. Removal



6. Remove the E-ring (1) at the right end of the turn roll assembly (2) (Asm-Index: 21-20, page 700).

7. Remove the right turn bearing (3) (Asm-Index: 21-21, page 700).

8. Disconnect J206 from the electromagnetic clutch aux (4).9. Slide the turn roll assembly (Asm-Index: 21-20, page 700) to the left to remove the left turn bearing from

the frame.

10. Remove the E-ring (5) securing the electromagnetic clutch to the turn roll assembly and remove theclutch from the turn roll.

Replacement1. Place the electromagnetic clutch aux. to the turn roll assembly.2. Reinstall the E-ring to secure the electromagnetic clutch to the turn roll assembly.3. Insert the turn roll assembly from the left and insert the notch of the electromagnetic clutch to the arm of

the frame.4. Insert the left side turn bearing to the frame.5. Install the right side turn bearing to the opening in the frame and secure the bearing using an E-ring.6. Reconnect J206 to the electromagnetic clutch.

Note: Route the harness so that it does not touch the gears.7. Reinstall the turn chute assembly aux. (See page 678).


9. Reinstall the feed housing right (See page 670).



Turn Roll AssemblyAsm-Index: 21-20, page 700.





6. Remove the electromagnetic clutch aux. (See page 693).

hc2m722F

1 2

3

54

Figure 114. Turn Roll Assembly Removal


7. Remove the right side E-ring (1) securing the turn bearing (2) (Asm-Index: 21-21, page 700) to the turnroll assembly (3) and remove the right side turn bearing.

8. Remove the two left side E-rings (4) securing the turn bearing (5) to the turn roll assembly and removethe left side turn bearing.

9. Slide the turn roll assembly to the left and release its right end from the frame.10. Slide the turn roll assembly to the right then backward and remove it from the frame.

Replacement



Parts Catalog

Assembly 20: Optional Tray 2/3 Feeder I

hc2m704F

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 91. Assembly 20: Optional Tray 2/3 Feeder I

Asm–Index Grid


20– Optional tray feeder I

–1 A3 90H0717 1 500 Sheet Feeder w/A4 Cassette (with 20-2∼20-28)


–2 A2 NP 1 v Feeder Frame Assembly (same as 21-2)

–3 A3 NP 1 v Feed housing, left

–4 A4 NP 1 v Feed housing, right

–5 A3 NP 1 v Feeder front housing

–11 B4 90H0771 1 v Feeder PWB

–12 B4 90H0772 1 v Tray lower2 harness

–14 B2 90H0773 1 v Turn in chute

–15 C1 90H3348 1 v Turn chute assembly, auxiliary

–16 B2 90H0775 1 v Cassette guide assembly, left (with 20-17∼20-22, 20-28)

–17 C2 NP 1 v v Cassette guide L

–18 C3 NP 4 v v Size actuator

–19 C3 NP 1 v v Size actuator spring

–20 B2 NP 1 v v Low paper actuator

–21 C3 90H0776 1 v v Cassette no paper sensor

–22 C3 90H0772 1 v v Feeder harness

–28 C3 NP 1 v v Cassette guide cap

–23 B1 90H0777 1 v Cassette guide assembly, right (with 20-24, 20-25)


Table 91. Assembly 20: Optional Tray 2/3 Feeder I (continued)

Asm–Index Grid


20– Optional tray feeder I

–24 B1 NP 1 v v Cassette guide R

–25 B1 NP 1 v v Cassette stopper spring

–26 B2 90H0778 1 v Cassette no paper actuator

–27 B4 90H3352 1 v Tray upper harness

Asm–Index numbers not used: 6 to 10, 13


Assembly 21: Optional Tray 2/3 Feeder II

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m705F


Table 92. Assembly 21: Optional Tray Feeder II

Asm–Index Grid


21– Optional tray feeder II



–2 A2 NP 1 v Feeder frame assembly

–3 B2 NP 1 v Feeder connector

–11 B2, C2 4 v Feed roll (in feed roll kit 90H0779)

–12 C2 90H0780 1 v Feed shaft assembly

– 90H0781 1 v Feed core assembly kit (with 21-13∼15, 21-17)

–13 B4 1 v v Feed core (in kit P/N 90H0781) (see page 580)

–14 B4 1 v v Feed core spring (in kit P/N 90H0781) (see page 580)

–15 B4 1 v v Feed gear (in kit P/N 90H0781) (see page 580)

–17 B4 1 v v Feed spring (in kit P/N 90H0781) (see page 580)

–16 A1, B3 2 v Feed bearing (in kit P/N 06L9997) (see page 580)

–18 A4 90H0782 v Feed solenoid

–19 C4 90H3355 1 v Electromagnetic clutch, auxiliary

–20 C2 90H0784 1 v Turn roll assembly

–21 A1 2 v Turn bearing (in kit P/N 90H0786) (see page 580)

–22 B3 1 v Feed idler gear (in kit P/N 90H3384) (see page 580)

–23 B3, C3 2 v Out idler gear (in kit P/N 90H3384) (see page 580)


Table 92. Assembly 21: Optional Tray Feeder II (continued)

Asm–Index Grid


21– Optional tray feeder II

–24 A4 1 v In idler gear (in kit P/N 90H3384) (see page 580)



Appendix H. 2000-Sheet Input Drawer OptionImportant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .707Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708

03 2000-SHEET COVER OPEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70815 TRAY n NOT READY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70917 2000 SHEET INPUT ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71026 PAPER JAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711


2000-Sheet Input Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718

Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .719Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720

HCF Tray Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722

Side Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .723Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724

Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .726

Lift Up Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .728

Bottom Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .729



Near Empty Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732

Lower Position Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .733Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .733Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734

Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736

Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .738

Paper Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .739Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .740

Transport Unit Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742

Right Hand Cover Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744

Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .745Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .746

Feed Roller Kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .747Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748

Upper Limit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750

Appendix H. 2000-Sheet Input Drawer Option 704


Paper Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .752Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .752Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753

Feed Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .754Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .754Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .755

Tray Set Sensor 1,2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .757

Left Hand Cover Open Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759

Transport Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .760Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .760Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .761

LVPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .763

Rear Cover Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .764Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765

Transport Roll Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .766Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767

Flat Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .768Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .769

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .770



Connector Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .772Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .773Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .773

Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774Assembly 40: 2000-Sheet Input Drawer I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774Assembly 41: 2000-Sheet Input Drawer Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .776Assembly 42: 2000-Sheet Input Drawer II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .778


Important InformationNote: When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power

switches. One cord connects the option to the wall outlet, and the other connects the option to theprinter. AC power is present on both machines even when both power switches are turned off.


Diagnostics

03 2000-SHEET COVER OPENOne of the two interlock switches on the rear cover of the HCF is not activated.

Note: This error can occur if the cover is opened, but the jammed paper is not removed.

Switch the power off and then on. If 26 PAPER JAM occurs, go to “26 PAPER JAM” on page 711.

Use “D21 SENSOR TEST” on page 261 to isolate help isolate the problem.Table 93. 03 2000-SHEET COVER OPEN


SUSPECT COMPONENTS

v Right Cover Open Switch (Asm-Index: 42-9, page 778), see page 743for the removal procedure.

v Left Cover Open Switch (Asm-Index: 42-20, page 778), see page 758for the removal procedure.

v HCF Rear Cover (Asm-Index: 42-2, page 778), see page 764 for theremoval procedure.

v Flat harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.

v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for theremoval procedure.


15 TRAY n NOT READYThe paper tray for the 2000-Sheet Input Drawer (High Capacity Feeder; HCF) is open, or the ″elevator″ for thestack of paper is in motion. If this error displays, wait 2 minutes. If it becomes a 26 PAPER JAM, go to “26PAPER JAM” on page 711.Table 94. 15 TRAY n NOT READY


SUSPECT COMPONENTS

v Obstruction from Right Casterv Tray Set Sensor 1 (Asm-Index: 42-18, page 778), see page 756 for the

removal procedure.

v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.

v Harness (Asm-Index: 41-16, page 776), see page 737 for the removalprocedure.

v HCF LVPS (Asm-Index: 42-25, page 778), see page 762 for theremoval procedure.


17 2000 SHEET INPUT ERRORThe 2000-Sheet Input Option (High Capacity Feeder; HCF) is installed, but is not detected. Ensure that theoption is installed correctly.Table 95. 17 2000 SHEET INPUT ERROR


SUSPECT COMPONENTS

v HCF power problem (The HCF should be plugged to the wall. Theprinter should be plugged to the HCF. Both power switches must beon).

v HCF LVPS (Asm-Index: 42-25, page 778)), see page 762 for theremoval procedure.

v Flat Harness (Asm-Index: 42-29, page 778), see page 768 for theremoval procedure.

v Harness (Asm-Index: 41-16, page 776), see page 737 for the removalprocedure.


26 PAPER JAMThere is a jam condition at the 2000-Sheet Input Option (High Capacity Feeder, HCF). This error is posted forseveral different conditions:v Paper never arrived at the HCF exit sensor actuator, located on the back door (chute) of the HCF.v Paper arrived at the the HCF exit sensor, but it never deactuated.v HCF tray (″elevator″) does not travel up or down correctly. (A 15 TRAY n NOT READ message will probably

display first and then turn into a 26 PAPER JAM message.)

Notes:1. When the 2000-Sheet Paper Tray Option is installed, there are two power cords and two power switches.

One cord connects the option to the wall outlet, and the other connects the option to the printer. ACpower is present on both machines even when both power switches are turned off.

2. If HCF option is installed directly beneath the printer, it is ″Tray 2″. If a 500-sheet option is installedbeneath the printer, it is Tray 2 and the HCF is Tray 3. In this MAP, generally the term Tray n is used.

3. It is normal for the HCF tray (″elevator″) to move after the printer power is turned on. It will move the trayup toward the top position where a sensor checks for a stack of paper. If no paper is detected, the traymoves all the way down (the position needed for paper loading). While the tray is moving, the operatorpanel may display a 15 2000-SHEET INPUT NOT READY message.

4. When the HCF tray is opened , the 15 2000-SHEET INPUT NOT READY message will display. Theelevator should move down until it reaches its lowest position. After the tray is closed, the elevator shouldmove up until the top of the stack of paper reaches the top position. (If there is no paper, it will move backdown.)

SUSPECT COMPONENTS1. HCF pick problem (paper never leaves HCF tray, but paper loading is OK):v Feed Roller (Asm-Index: 41-14, page 776)

v Feed Motor (Asm-Index: 42-28, page 778)


v Flat Harness (Asm-Index: 42-29, page 778)

2. HCF transport problem (paper gets picked and starts to leave the tray, but does not continue into paperpath):v Transport Motor (Asm-Index: 42-21, page 778)

v Transport Belt (Asm-Index: 42-22, page 778)

v Transport Gear (Asm-Index: 42-23, page 778)

v Transport Roll (Asm-Index: 42-7, page 778) - test with “D68 HCF MOTOR (HCF Transport Motor)” onpage 291

v Flat Harness (Asm-Index: 42-7, page 778)

v Paper Chute (Asm-Index: 42-5, page 778)

3. HCF elevator problem:v Test with “D44 HCF UP (Tray Lifts)” on page 273 & “D45 HCF DOWN (Tray Lowers)” on page 275

v Lift up motor (Asm-Index: 41-10, page 776)

v Lower position sensor (Asm-Index: 41-12, page 776)

v Upper limit sensor (Asm-Index: 42-11, page 778), test with “D21 SENSOR TEST” on page 261

v Paper level sensor (Asm-Index: 42-2, page 778)

4. Sensor Problems that cause false 26 errors after power is turned on:v HCF exit sensor (42-10)- test with “D21 SENSOR TEST” on page 261

v Tray set #2 sensor (42-19) - 15 message will occur first - test with “D21 SENSOR TEST” on page 261

5. Sensor Problems that cause 26 during printing from HCF:v HCF exit sensor actuator (Asm-Index: 42-5, page 778)

v HCF exit sensor (42-10) - test with “D21 SENSOR TEST” on page 261

v No paper sensor (Asm-Index: 42-28, page 778) - test with “D21 SENSOR TEST” on page 261


v Paper level sensor (Asm-Index: 42-2, page 778)

Note: The HCF near empty sensor is not used

6. General FRUs for 26 Jam (valid in all of the lists above)v HCF LVPS (Asm-Index: 42-25, page 778)

v Cables (check all connections at HCF LVPS)v HCF optionv MCU



1.

Switch on the printer power and the HCF power. Wait until the printer isready or an error displays.

Is there an error?

If the initial error is26, go to step 3. Ifthe initial error is15, go to step 2.

Go to step 4

2.

Wait 2 minutes to see if the 15 error turns into a 26 PAPER JAM.

Does a 26 PAPER JAM display?

Go to step 4 For other errors,go to “Chapter 1.Getting Started”on page 25.

3.

Open the rear door of the HCF.

Is there any paper or paper scraps in the path?

Remove thepaper. Open andclose the topcover to reset theerror. Go to step4.

False 26 errors.Go to SuspectComponents list 4,then 3 and 6.




4.

ELEVATOR FUNCTION:

Put paper in the HCF tray. The elevator should go down when you open thetray and then go up when you close the tray. A 15 message is normal duringtray motion, but it should not turn into a 26.

Does the Elevator function correctly?

Go to step 5 Go to SuspectComponents, lists3 and 6.

5.

Print from the HCF:a. Set PAPER MENU/SOURCE=Tray2 or Tray3.b. Ensure that there is paper in the HCF.c. Go OFFLINE.d. Use TEST MENU/CONFIG PAGE.

Does the CONFIG page print correctly?

Go to step 6 For 26 PAPERJAMs, go to step7. For otherproblems, go toStart of Call.

6.

a. Remove the paper from the HCF.b. Set PAPER MENU/TRAY SWITCH=off.c. Try to print another CONFIG page.

Does an 11 LOAD message occur?

Unknown problem.If the problempersists, install anew HCF option.

If a 26 erroroccurs, install anew HCF nopaper sensor(Asm-Index:42-28, page 778).

7.

Open the rear door of the HCF.

Did the paper start to leave the HCF tray?

Go to step 8 Pick problem. Goto SuspectComponents, lists1 and 6.




8.

Run D68 (see “D68 HCF MOTOR (HCF Transport Motor)” on page 291). Youwill have to override the HCF rear cover switches to watch the transport rollmove.

Does the Transport Roll move?

Go to step 9 Transportproblem. Go toSuspectComponents, lists2 and 6.

9.

You have a problem caused by one of the following:v HCF exit actuator (Asm-Index: 42-5, page 778)

v HCF exit sensor (42-10) - test with “D21 SENSOR TEST” on page 261

v Paper path obstruction

10.End of Diagnostic


Wiring Diagram

RIGHT HAND COVEROPEN SWITCH

LEFT HAND COVEROPEN SWITCH

TRANSPORT MOTOR

SENSOR

TRAY SET SENSOR 1

PAPER LEVEL SENSOR

ENCODER

FEEDMOTORCONTROL

NO PAPER SENSOR

UPPER LIMIT SENSOR

TRAY SET SENSOR 2

SIZE SENSOR

NEAR EMPTY SENSOR

LOWER POSITION SENSOR

LIFT UP MOTOR

P/J:M1

P/J:S2

P/J:S7

P/J:S11

P/J:S3

P/J:P1

P/J:S1

P/J:XS4

P/J:P2

P/J:S10

P/J:S6

P/J:S12

P/J:S9

P/J:M2

P/J:S8

LIFT UPMOTORCONTROL

CPU

SG

P/J:XS3RXDTXDSGSG

FEEDER CHECK

BaseEngine

or

2ND TRAY

(+)( - )

13

13

13

21

13

321

54

123

123

1234

12

123

12

12

GNDGND

FG

DC21

DC22

DC22

SWHD

SGSWPL(TTL)

SGSWPSZ(TTL)

DC21SWHU1

SWHU1SWHU2

+5VDC

LSPE(TTL)

SG

DC11DC12

+5VDC

ENCOD(TTL)

SG

+5VDC

LSPL(TTL)

SG

SWCPR(TTL)

SG

+5VDC

LSPEX(TTL)

SG

SM1

SM2

SM3

SM4

SWDO1(TTL)

SWDO(TTL)

SWDO1(TTL)

SG

FEED MOTOR

141612139

12345

P/J:XS110912

56

78

34

P/J:XS2

1211

2526

12

345

678

222324

910

131415

18192021

1617

2728

TRANSPORTMOTORCONTROL

MAIN SWITCHAC to DC

SERVICE CONNECT

AC INLET

LVPS

M

M

M

This is an internal wiring of the FEED ROLLER KIT,therefore the P/J No. and Pin No. are omitted.hc2m089F



2000-Sheet Input DrawerAsm: 40, page 774.

[ 1 ]

hc2m072F

1

Figure 115. 2000-Sheet Input Drawer Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Paper Cassette from the Base Engine or Option Tray.4. Remove the two screws (1) that lock the HCF to the Base Engine.

5. Lift the Base Engine to separate the Base Engine and the HCF. Remove the HCF.

Replacement

Attention: In the step below, match the HCF positioning boss with the Base Engine positioning boss.Gently place the main unit on the HCF; make sure it goes on straight.

1. Lift the Base Engine and install it on the HCF.2. Lock the Base Engine and the HCF with the two screws.3. Install the paper cassette, if Base Engine or Option Tray is installed.


FootAsm-Index: 40-3, page 774.

hc2m024F1

2

2 1

Figure 116. Foot Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the four screws (1) that lock the Foot (2). Remove the Foot.

Replacement



HCF Tray AssemblyAsm-Index: 41-1, page 776.

hc2m023F

[ 1 ][ 2 ]

[ 3 ] [ 4 ]

1

2

1

Figure 117. HCF Tray Assembly Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Disconnect the P/J:XS1 (See 1 in the figure).Attention: In the next step, carefully sqeeze the release hooks on the clamp from the backside. The hooksbreak easily.5. Remove the harness clamp (See 2 in the figure).6. Remove the two screws (1) securing the HCF Tray Assembly (2).7. Remove the hooks (See 3 in the figure) on the front side of the slide rails. (The hooks lock the HCF Tray

Assembly.)Attention: When you remove the HCF Tray Assembly in the step below, support the Tray (rear) so that it willnot fall.8. Remove the hooks (See 4 in the figure) on the rear side of the slide rails. (The hooks lock the HCF Tray

Assembly.)

Replacement1. Install the rear hooks on the HCF Tray Assembly.2. Install the front hooks on the HCF Tray Assembly.3. Lock the HCF Tray Assembly with the two screws .4. Install the harness clamp.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.5. Connect the P/J:XS1.6. Insert the HCF Tray Assembly into the HCF.


Side PlateAsm-Index: 41-3 and 41-13, page 776.

hc2m025F

1

1

Figure 118. Side Plate Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Turn the keys that lock the Side Plates (1).5. Remove the Side Plates.

Replacement



Front CoverAsm-Index: 41-7, page 776.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the four screws (1) that lock the Front Cover (2).5. Remove the Front Cover.

hc2m026F

2

1

1

Figure 119. Front Cover Removal


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 MotorAsm-Index: 41-10, page 776.

-

+

P/J:M1-(-)

P/J:M1-(+)

Black

Red

[ 1 ][ 2 ]

hc2m027F1

2

3

Figure 120. Lift Up Motor Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Front Cover (See page 725).

5. Disconnect the P/J :M1.Attention: When you remove the Lift Up Motor in the steps below, place an object or your hand on theBottom Plate to prevent it from springing up.6. Remove the two screws that lock the Lift Up Motor. You can also remove the motor by just loosening

them.7. Remove the E-ring.8. Remove the Lift Up Motor.

Replacement1. Install the Lift Up Motor.2. Install the E-ring.Attention: When you lock the Lift Up Motor in the step below, the tube washer should not overlap thepositioning post. (See 1 in the figure.)3. Lock the Lift Up Motor with the two screws.Attention: In the step below, check the cable color when connecting the P/J. If the P/J is not connectedproperly, the system malfunctions or may be damaged. (See 2 in the figure). When you connect the P/J in thestep below, make sure that the harness or other components are not touching the motor’s rotatingcomponents.If they come in contact with the rotating components, they will be damaged.4. Connect the P/J :M1.5. Install the Front Cover (See page 725).

6. Insert the HCF Tray Assembly into HCF.


Bottom PlateAsm-Index: 41-2, page 776.

[ 1 ]

[ 2 ]

[ 3 ]

hc2m046F

1

1

1

Figure 121. Bottom Plate Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Plates (See page 723).

5. Remove the locks (see 1 in the figure) on the Bottom Plate (1) (use a screwdriver if necessary).6. Lift the back side of the Bottom Plate, remove the Bottom Plate (See 2 in the figure).

Replacement

Attention: When you install the Bottom Plate in the step below, make sure that the rear roller in the LiftUp mechanism has been properly installed on the roller guide of the Bottom Plate (See 3 in the figure).

1. Install the Bottom Plate.2. Lock the Bottom Plate (use a screwdriver if necessary).3. Install the Side Plates (See page 723).

4. Insert the HCF Tray Assembly into the HCF.


Near Empty SensorAsm-Index: 41-11, page 776.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.

hc2m028F

1

Figure 122. Near Empty Sensor Removal


4. Remove the Front Cover (See page 725).

5. Remove the Near Empty Sensor.6. Disconnect the P/J:S1.

Replacement

Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.

1. Connect the P/J:S1.Attention: In the step below, install the Near Empty Sensor to the correct direction, otherwise the sensor pinsmay be damaged.2. Install the Near Empty Sensor (1).3. Install the Front Cover (See page 725).

4. Insert the HCF Tray Assembly.


Lower Position SensorAsm-Index: 41-12, page 776.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Panels (See page 723).

hc2m029F

1

Figure 123. Lower Position Sensor Removal


5. Remove the Bottom Plate (See page 729).

6. Remove the Lower Position Sensor (1).7. Disconnect the P/J:S2.

Replacement


1. Connect the P/J:S2.Attention: In the step below, install the Lower Position Sensor to the correct direction, otherwise the sensorpins may be damaged.2. Install the Lower Position Sensor.3. Install the Bottom Plate (See page 729).

4. Install the Side Plates (See page 723).



Size SensorAsm-Index: 41-15, page 776.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Remove the Side Plates (See page 723).

hc2m073F

1

Figure 124. Size Sensor Removal


5. Remove the Bottom Plates (See page 729).

6. Remove the Size Sensor (1).7. Disconnect the P/J:S3.

Replacement


1. Connect the P/J:S3.Attention: In the step below, install the Size Sensor to the correct direction, otherwise the sensor pins maybe damaged.2. Install the Size Sensor.3. Install the Bottom Plate (See page 729).

4. Install the Side Plates (See page 723).



HarnessAsm-Index: 41-16, page 776.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Pull out the HCF Tray Assembly.4. Disconnect the P/J:XS1 (See 1 in the figure).5. Remove the Front Cover (See page 725).

6. Remove the Bottom Plate (See page 729).

7. Remove the Holder (See 2 and 3 in the figure).8. Remove the cable clamp.

hc2m078F

White

Green

Gray Blue

Brown

Orange

-

+

Black

Red

[ 1 ][ 3 ]

[ 4 ] [ 7 ]

[ 6 ]

[ 5 ]

[ 8 ]

[ 2 ]

1

Figure 125. Harness Removal


9. Disconnect the P/Js that are connected to the following: Near Empty Sensor, Size Sensor , LowerPosition Sensor and Lift Up Motor.

10. Remove the Harness (1).

Replacement1. Install the Harness.Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.2. Connect the P/Js to the following: Near Empty Sensor, Size Sensor, Lower Position Sensor and Lift Up

Motor.3. Install the cable clamp.4. Install the Holder.5. Install the Bottom Plate (See page 729).

6. Install the Front Cover (See page 725).Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.

7. Connect the P/J:XS1.8. Insert the HCF Tray Assembly into the HCF.


Paper ChuteAsm-Index: 42-5, page 778.

[ 1 ]

hc2m032F

2

1

Figure 126. Paper Chute Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Rear Cover Kit (1) from the HCF (See page 764).

4. Remove the Paper Chute (2) from the Rear Cover Kit.

Replacement

Attention: When you install the Paper Chute in the step below, make sure that the four springs areinstalled properly, otherwise the system will malfunction (See 1 in the figure).

1. Install the Paper Chute to the Rear Cover Kit.2. Install the Rear Cover Kit to the HCF (See page 764).


Transport Unit AssemblyAsm-Index: 42-7 to 42-24, and 42-29, page 778.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.

hc2m045F

2

1

Figure 127. Transport Unit Assembly Removal


3. Remove the Rear Cover Kit from the HCF (See page 764).

4. Roll out the HCF Tray Assembly from the HCF.5. Disconnect the P/J:XS2 from LVPS.Attention: When you remove the screws in the step below, support the Transport Unit Assembly firmly withyour hand so that it will not fall.6. Remove the two screws (1) securing the Transport Unit Assembly (2).7. Remove the Transport Unit Assembly.

Replacement1. Install the Transport Unit Assembly.2. Secure the Transport Unit Assembly with the two screws.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.3. Connect the P/J:XS2 to LVPS.4. Insert the HCF Tray Assembly into the HCF.5. Install the Rear Cover Kit to the HCF (See page 764).


Right Hand Cover Open SwitchAsm-Index: 42-9, page 778.


hc2m041F

1

Figure 128. Right Hand Cover Open Switch Removal


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


1. Connect the P/J:S12.Attention: In the step below, install the Right Hand Cover Open Switch in the correct direction, otherwise theswitch pins may be damaged.2. Install the Right Hand Cover Open Switch.3. Install the Transport Unit Assembly (See page 741).


Exit SensorAsm-Index: 42-10, page 778.

hc2m035F

1

Figure 129. Exit Sensor Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the Transport Unit Assembly (See page 741).

4. Disconnect the P/J:S8.5. Remove the Exit Sensor (1).

Replacement1. Install the Exit Sensor.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:S8.3. Install the Transport Unit Assembly (See page 741).


Feed Roller KitAsm-Index: 42-28, page 778.

[ 1 ]

[ 3 ]

[ 2 ]

hc2m030F5

6

2

4

21

3

Figure 130. Feed Roller Kit Removal



4. Disconnect the P/J:P1 and P/J:P2 connected to the Feed Roller Kit Harness (1).5. Remove the harness clamp securing the Feed Roller Kit Harness .6. Remove the two Feed Roller Kit Springs (2).7. Remove the hooks (3) (See 1 in the figure) securing the Feed Roller Kit (4).8. Remove the Right Hand Feed Roller Bracket (5) and the Left Hand Feed Roller Bracket (6) (See 2 in the

figure)that lock the Feed Roller Kit.9. Remove the Feed Roller Kit.

Replacement


Attention: In the step below, check that the Feed Roller Kit properly pushes the Paper Level SensorActuator (See 3 in the figure).

1. Install the Feed Roller Kit.2. Fix the Feed Roller Kit on the Right Hand Feed Roller Bracket and Left Hand Feed Roller Bracket and

attach it to the frame in the Transport Unit Assembly.3. Secure the Feed Roller Kit using the hooks.4. Install the two Feed Roller Kit Springs.5. Secure the Feed Roller Kit Harness with the harness clamp.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.6. Connect the P/J:P1 and P/J:P2.7. Install the Transport Unit Assembly (See page 741).


Upper Limit SensorAsm-Index: 42-11, page 778.


4. Remove the Feed Roller Kit (See page 747).

5. Remove the Upper Limit Sensor (1).

hc2m036F

1

Figure 131. Upper Limit Sensor Removal


6. Disconnect the P/J:S11.

Replacement


1. Connect the P/J:S11.Attention: In the step below, install the Upper Limit Sensor to the correct direction, otherwise the sensor pinsmay be damaged.2. Install the Upper Limit Sensor.3. Install the Feed Roller Kit (See page 747).

4. Install the Transport Unit Assembly (See page 741).


Paper Level SensorAsm-Index: 42-12, page 778.


4. Remove the Feed Roller Kit (See page 747).

5. Disconnect the P/J:10.

hc2m037F1

Figure 132. Paper Level Sensor Removal


6. Remove the Paper Level Sensor (1).

Replacement1. Install the Paper Level Sensor.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:10.3. Install the Feed Roller Kit (See page 747).

4. Install the Transport Unit Assembly (See page 741).


Feed RollerAsm-Index: 42-14, page 778.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Open the Rear Cover Kit.4. Remove the Feed Roller (1).

hc2m038F

1

Figure 133. Feed Roller Removal


Replacement



Tray Set Sensor 1,2Asm-Index: 42-18 and 42-19, page 778.


4. Remove the Tray Set Sensors 1 (1) and 2 (2).

hc2m039F

21

Figure 134. Tray Set Sensor 1,2 Removal


Note: Label the wires before removing them in the next step.5. Disconnect the P/J:S6 and P/J :S7.

Replacement

Attention: In the step below, connect the P/J’s as labeled, otherwise the system malfunctions.1. Connect the P/J:S6 and P/J :S7.Attention: In the step below, install the Tray Set Sensors 1 and 2 in the correct direction, otherwise thesensor pins may be damaged.2. Install the Tray Set Sensors 1 and 2.3. Install the Transport Unit Assembly (See page 741).


Left Hand Cover Open SwitchAsm-Index: 42-20, page 778.


hc2m040F1

Figure 135. Left Hand Cover Open Switch Removal


3. Remove the Transport Unit Assembly (See page 741).

4. Remove the Left Hand Cover Open Switch (1).5. Disconnect the P/J:S9.

Replacement

Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the systemmalfunctions.1. Connect the P/J:S9.Attention: In the step below, install the Left Hand Cover Open Switch in the correct direction, otherwise theswitch pins may be damaged.2. Install the Left Hand Cover Open Switch.3. Install the Transport Unit Assembly (See page 741).


Transport MotorAsm-Index: 42-21, page 778.


hc2m042F

2

1

Figure 136. Transport Motor Removal


4. Disconnect the P/J:M2.5. Remove the two screws (1) securing the Transport Motor (2).6. Remove the Transport Motor.

Replacement1. Secure the Transport Motor with the two screws .Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:M2.3. Install the Transport Unit Assembly (See page 741).


LVPSAsm-Index: 42-25, page 778.

Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the HCF Tray Assembly (See page 721).

hc2m043F1

3

2

Figure 137. LVPS Removal


4. Disconnect the P/J:XS1, XS2, XS3.5. Remove the screw (1) securing the ground wire coming from LVPS (2).6. Remove the four screws (3) securing the LVPS to the HCF.7. Remove LVPS.

Replacement1. Secure LVPS to HCF with the four screws .2. Secure LVPS ground wire with the screw.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.3. Connect the P/J:XS1, XS2, XS3.4. Install the HCF Tray Assembly (See page 721).


Rear Cover KitAsm-Index: 42-26, page 778.

hc2m031F

1 2

Figure 138. Rear Cover Kit Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Open the Rear Cover Kit (1).

Note: In the step below, open the Rear Cover Kit halfway for easy removal.4. Remove the Screw (2) holding the strap.5. Remove the Rear Cover Kit.

Replacement



Transport Roll KitAsm-Index: 42-27, page 778.

[ 1 ]

hc2m033F

11

32

5

4

Figure 139. Transport Roll Kit Removal



4. Remove the two E-rings (1).5. Remove the Gear (2).6. Remove the Left Hand Lock (3).7. Remove the Right Hand Lock (4).8. Remove the Transport Roll (5).

Replacement1. Install the Transport Roll.2. Install the Right Hand Lock.3. Install the Left Hand Lock.Attention: In the step below, install the Gear so that the belt guard (See 1 in the figure) is to the outside.4. Install the Gear.5. Install the five E-rings.6. Install the Transport Unit Assembly (See page 741).


Flat HarnessAsm-Index: 42-29, page 778.


hc2m044F

1

Figure 140. Flat Harness Removal


4. Disconnect all P/Js connected to the Flat Harness.5. Remove all harness clamps securing the Flat Harness.6. Disconnect the Flat Harness (1).

Replacement1. Connect the Flat Harness.2. Secure Flat Harness with the harness clamps.Attention: In the step below, connect the P/J to the pin indicated by the arrow, otherwise the system willmalfanction.3. Connect the P/Js.4. Install the Transport Unit Assembly (See page 741).


BeltAsm-Index: 42-22, page 778.


hc2m079F

1

Figure 141. Belt Removal


4. Remove the Transport Motor (See page 760).

5. Remove the Belt (1).

Replacement



Connector KitAsm-Index: 42-32, page 778.

[2]

[1]

hc2m080F

1

2

Figure 142. Connector Kit Removal


Removal1. Switch off printer power and HCF power. Unplug the HCF power cord from the wall.2. Remove paper from the HCF Tray.3. Remove the HCF from the Base Engine (See page 717).

4. Disconnect the P/J:XS3 (See 1 in the figure).5. Remove the two screws (1) securing the Connector Kit (2).6. Disconnect the Connector Kit.

Replacement1. Connect the Connector Kit.Attention: In the step below, connect the P/J in the correct direction, otherwise the P/J pins may bedamaged.2. Connect the P/J:XS3.3. Secure the Connector Kit with the two screws.4. Install the Base Engine.


Parts Catalog

Assembly 40: 2000-Sheet Input Drawer I

1 (with 1A-18)

3

4

4

3

4

45

11

11

14

15

2. (PL42.1)10

10

12

1216

17

hc2m020F

18 (with 16,17)

19 (with 4,5)

1A (PL41.1)

13

13

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 97. Assembly 40: 2000-Sheet Input Drawer I

Asm–Index Grid


40– 90H0720 High-capacity feeder I

–1 A3 NP 1 v High-capacity tray assembly (with 40-2∼40-18)

–1A A2 NP 1 v High-capacity input drawer tray (same as 41-1)

–2 A4 NP 1 v v High-capacity feeder assembly (same as 42-1)

–3 B2, C3 90H3469 2 v v Foot

–6 NP v v Wingnut

–7 NP v v Disk

–8 NP v v Disk

–10 A3, A4 11L5342 2 v v HCF Screw

–11 B4 90H3472 2 v v Castor, Non-Locking

–12 B2, B3 11L5343 2 v v HCF Locking Castor

–13 B1 11L5357 2 v v Drawer Castor

–14 and–15

A2, A3 11L5344 1 v v E-ring and Clip

–18 C1 90H3471 1 v v Rails (with 40-16 and 40-17)

–16 B2 NP 1 v v v Rail

–17 B1 NP 1 v v v Rail

–19 C1 90H3470 1 v Hex Screw (with 40-4 and 40-5)

–4 B3, C3,C4

NP 4 v v Hex screw

–5 C2 NP 1 v v Hex key


Assembly 41: 2000-Sheet Input Drawer Tray

1 2 3 4

1 2 3 4

A

B

C

A

B

C

hc2m021F

1 (with 2-18)19 (with 4,5)

2

134

4

35

5

14

1414

6

141215

18

17

17

16

18

7

89

9

10

11


Table 98. Assembly 41: 2000-Sheet Input Drawer Tray

Asm–Index Grid


41– 90H0720 High-capacity feeder tray

–1 A4 NP 1 v High-capacity input drawer tray (with 41-2∼41-18)

–2 A4 NP 1 v v Bottom plate

–3 B4 NP 1 v v Right hand side plate

–6 B4 NP 1 v v Tray frame assembly

–7 B1 90H3474 1 v v Front cover

–8 C2 NP 1 v v Bearing

–9 C2 NP 2 v v Ring

–10 C2 90H3475 1 v v Elevator motor

–11 C2 90H3476 1 v v Paper low sensor

–12 B3 90H3477 1 v v Lower position sensor

–13 A3 NP 1 v v Left-hand side plate

–14 B3 11L5346 4 v v HCF Centering Format

–15 B2 11L5347 1 v v HCF Size Sensor

–16 A2 11L5348 1 v v HCF Harness

–17 A1, B2 11L5349 2 v v HCF Holder

–18 B1, B2 11L5350 2 v v HCF Clamp

–19 A2 90H3473 1 v HCF Key and Lock (with 41-4 and 41-5)

–4 A3, A4 NP 2 v v Key

–5 B3 NP 2 v v Lock


Assembly 42: 2000-Sheet Input Drawer II

2321

22

24

2920

10

7

13

19

18 1211

98

hc2m022F

1 (with 2-25,29-31,33-36) 26 (with 2,4,5,33)

32 (with 30,31)

35

27 (with 7,8,24,35,E-RINGx1,KL-CLIPx1)

17

14

15

16

36

28 (with 14-17,36)

30

3131

4

44

4

5

2

6

34

34

33

25

1 2 3 4

1 2 3 4

A

B

C

A

B

C


Table 99. Assembly 42: 2000-Sheet Input Drawer II

Asm–Index Grid


42– 90H0720 High-capacity feeder II

–1 A2 NP 1 v High-capacity feeder unit (with 42-2∼42-25, 42-29∼42-31, and 42-33∼42-36)

–2 A4 1 v v Rear cover (in kit P/N 90H3478) (see page 580)

–4 A3, A4 4 v v Spring (in kit P/N 90H3478) (see page 580)

–5 A3 1 v v Paper chute (in kit P/N 90H3478) (see page 580)

–6 B4 NP 1 v v Feeder frame assembly

–7 B3 1 v v Transport roll (in kit P/N 90H3479) (see page 580)

–8 C3 1 v v Right-hand lock (in kit P/N 90H3479) (see page 580)

–9 C2 90H3481 1 v v Right-hand cover open switch

–10 B2 90H3482 1 v Sensor

–11 C2 90H3483 1 v v Upper limit sensor

–12 C1 90H3484 1 v v No paper sensor

–13 C1 NP 1 v v Frame

–14 C2 1 v v Feed roller (in kit P/N 90H3480) (see page 580)

–15 C2 1 v v Feed roller bracket (in kit P/N 90H3480) (see page 580)

–16 C2 1 v v Right-hand feed roller bracket (in Kit P/N 90H3480) (see page 580)

–17 C1 1 v v Left-hand feed roller bracket (in Kit P/N 90H3480) (see page 580)

–18 C1 90H3485 1 v v Tray set sensor 1

–19 C1 90H3486 1 v v Tray set sensor 2

–20 B1 90H3487 1 v v Left-hand cover open switch


Table 99. Assembly 42: 2000-Sheet Input Drawer II (continued)

Asm–Index Grid


42– 90H0720 High-capacity feeder II

–21 A1 90H3488 1 v v Transport motor

–22 B1 90H3489 1 v v Belt

–23 A1 06L9750 1 v v Gear

–24 B2 1 v v Left-hand lock (in kit P/N 90H3479) (see page 580)

–25 A2 06L9996 1 v v Low voltage power supply

–29 B1 11L5351 1 v v HCF Flat Harness

–30 A3 1 v v Connector harness (in kit P/N (see page 580) 11L5352)

–31 A3 NP 1 v v Screw

–33 A4 1 v v Strap (in kit P/N 90H3478) (see page 580)

–34 A4, B4 11L5353 2 v v HCF Clamp

–35 B1 1 v v Spacer (in kit P/N 90H3479) (see page 580)

–36 C2 1 v v Spring (in kit P/N 90H3480) (see page 580)

–26 A3 90H3478 1 Kit, rear cover (with 42-2∼42-5, and 42-33)

–27 B2 90H3479 1 Kit, transport roll (with 42-7, 42-8, 42-24, 42-35, E-ring, and KL-Clip)

–28 C2 90H3480 Kit, feed roller (with 42-14∼42-17, and 42-36) (includes the feed motor)

–32 A2 11L5352 1 HCF Connector Kit (with 42-30 and 42-31)


GlossaryThe following terms are defined as they are used in this publication. If you do not find the term you need, seethe IBM Dictionary of Computing, New York, McGraw-Hill, 1994, or the IBM Dictionary of Printing.

The following cross-references are used in this glossary:v Contrast with refers to a term that has an opposite meaning.v See refers to a preferred term with the same meaning.v See also refers to related terms.

AA4-size paper. Paper that is 210 by 297 mm (8.3 x 11.7 in.).

ac. Alternating current

asm. Assembly

attention notice. An attention warns of possible of damage to a program, device, system, or data. Attention notices are locatedthroughout this publication. Attention notices are not translated.

aux. Auxiliary

BB5-size ISO paper.. Paper that is 176 mm by 250 mm (6.93 in. by 9.84 in.). B5-size JIS paper. Paper that is 182 mm by 257mm (7.17 in. by 10.12 in.).

BCR. Bias charge roller.

BTR. Bias transfer roller.


Ccaution notice. A notice that calls attention to a condition that is potentially dangerous to people.

CCW. Counterclockwise

charge. The negative voltage that the HVPS applies to the surface of the drum.

CM. Charge metering.

continuity. A resistance reading of approximately zero (0) ohms.

CR. Signal name for the charge voltage.

CRU. Customer replaceable unit, such as the EP cartridge.

CW. Clockwise

Ddanger notice. A notice used to call attention to a condition that is potentially deadly or extremely dangerous.

DB. Signal name for the developer bias voltage.

dc. Direct current.

default. An adjustment or setting that is set at the time of equipment manufacture.

detack. Separating the toned sheet of paper from the surface of the drum after imaging.

develop. The process when toner adheres to the latent image on the drum.

developed image. The visible image on the drum after going through the development process.

DPI. Dots per inch. The number of dots per inch printed by a laser printer. Each dot is either on or off, printed or not printed.See also (PPI).

DRAM. Dynamic random-access memory.

Glossary 782

drum. The electrophotographic receptor.

DTS. Signal name for the deteck saw voltage.

duplex. Printing on both sides of a single sheet of paper.

EEP. Electrophotographic.

EP cartridge. The electrophotographic cartridge; sometimes referred to as the print cartridge, the toner cartridge, or as theCRU.

error code. A unique set of letters and numbers that the printer displays to indicate that a problem exists in a specific area ofthe printer.

ESD. Electrostatic discharge, which if discharged into the circuitry of an integrated circuit, can damage the circuit.

exposure. The action of the laser beam striking and discharging select areas of the electrically charged surface of the drum.

FFG. Frame ground.

FU. Face-up. This abbreviation is used in some display messages.

fuser. The printer subsystem that uses heat and pressure to permanently adhere, or fuse, a transferred toner image to a sheetof paper.

Gground. Electrical ground.

Glossary 783

Hharness. A bundle of wires that form a single unit and are generally terminated with connectors at both ends.

HCF. High capacity feeder, or 2000-Sheet Input Drawer

HCI. High capacity input

high. A signal voltage that is equal to or almost equal to the base voltage; such as +5 V dc or +24 V dc. See also low.

HVPS. High voltage power supply.

Iimage density. The relative darkness of the latent image on a sheet of paper.

image development. Toner turning the latent image into a visible image. See also develop.

image fusing. Using heat and pressure to permanently adhere a toned image to a sheet of paper.

image transfer. Moving the developed image from the surface of the drum to the surface of a sheet of paper.

interlock. Interlock switch. Used as a safety measure to remove voltage from circuits whenever a printer cover or the like isopened.

JJ. Jack. A female electrical connector. See also P and P/J.

KKB. Kilobyte. 1 024 bytes.

Kb. Kilobit. 1 024 bits.

Glossary 784

Llaser. Refers to the laser diode or to the laser beam.

laser diode. Generates the laser beam that is used in the laser unit.

laser beam path. The path that the laser beam takes, through lenses and mirrors, from the laser diode to the surface of thedrum.

latent image. The visible, electrical image remaining on the surface of the drum after exposure.

LCD. Liquid crystal diode.

LED. Light emitting diode.

LEF. Long edge feed.

legal-size paper. Paper that is 216 mm x 356 mm (8.5 in. x 14.0 in.). letter-size paper. Paper that is 216 mm x 279 mm (8.5 in.x 11.0 in.).

low. A signal voltage that is significantly lower than the base voltage. See also high.

LVPS. Low voltage power supply.

MMB. Megabyte. 1 024 000 bytes.

Mb. Megabit. 1 024 000 bits.

MBF. Multi-bypass filter.

MCU. Machine control unit.

Glossary 785

NNC. No connection.

NOP. No paper.

NVRAM. Non-volatile random access memory.

PP. Plug A Male electrical connector.See also J and P/J.

P/J. Plug/jack. A connected male (plug) and a female (jack). See also J and P.

pel. See pixel.

pixel (pel). (1) The smallest distinct element of a raster image or an image displayed on a monitor. (2) The elementarygraphical cell that constitutes an image. (3) An element of a raster pattern or a point where a toned area on a photoconductorcan appear. Pixels per inch (ppi). The number of pixels per linear inch. Unlike dots, which are bilevel entities, pixels can holdmultiple levels of information. See also dots per inch.

point. A unit of measurement for describing type sizes. There are 12 points to a pica; about 72 points to an inch.

PPI. Pixels per inch. See also dots per inch (DPI).

PPM. Pages per minute.

print surface. The side of a sheet of paper that receives the printed image.

RRTN. Return.

Glossary 786

SSEF. Short edge feed.

sensor. A device used to monitor a function or an operation, such as paper travel along the paper path.

SG. Signal ground.

signal name. A name given to a wire indicating the purpose of the wire and/or the voltage carried by that wire.

SIMM. Single inline memory module.

simplex. Generally means printing only on one side of a sheet of paper. See also duplex.

SOS. Start of scan.

Ttoggle. To switch between two states, such as on and off or up and down.

toner. The dry ink that is used to create the visible image. Toner is stored in the EP cartridge.

TR. Signal name for transfer current.

transfer. Moving the toner image (developed image) from the surface of the drum to the surface of a sheet of paper.

Glossary 787

IndexAasm. locations

duplex 362env. feeder 362printer 362

assembly locations 547

Bbooks, obtaining from web 603

Ccable

ESD (electrostatic discharge) 20cable, ESD (electrostatic discharge)

20CAUTION notice 7cleaners and lubricants 588clutch locations

env. feeder 364printer 364

code updates, obtaining from web 603commonly used

fasteners 588parts 587

completing your task 36components, electrical, location 364connector locations

printer 367

DDANGER notice 6defects, print quality 34detergent 588diagnostic quick path 28diagnostics

See getting started 25test prints, running

paper path 251disposal of materials 8documents, obtaining from web 603

Eelectrical system

safety 8error codes and messages 30

000–099 30, 31, 32ESD

procedures 20

Ffasteners, common 588fault isolation

See diagnostic quick path 28fixes, obtaining from web 603

Ggathering information 26getting started 25

grease 588ground wires, locating 13guides, obtaining from web 603

Hhome page, Printing Systems Company

603

Iinformation, gathering 26instructions, safety inspection 12intermittent problems or errors 133

Llaser safety 10locations

asms.duplex 362env. feed 362printer 362

clutchesenv. feeder 364printer 364

connectorsprinter 367

electrical components 364clutches, solenoids 364miscellaneous 390sensors 384


locations (continued)mechanical

duplex 391printer 390

mechanical components 390PCBs


quick path 361sensors

duplex 384, 386env. feeder 384, 386printer 384, 386

solenoidsenv. feeder 364printer 364

switchesduplex 384, 386env. feeder 384, 386printer 384, 386

lubricants and cleaners 588

Mmanuals, obtaining from web 603marking actions as completed, safetyinspection 13

mat, ESD 20mechanical, locations 390mechanical locations


messagesSee error codes and messages 29

miscellaneous, locations 390

NNetwork Interface Card 541NIC 541notices

electrostatic discharge (ESD) 20safety

CAUTION 7DANGER 6description 6

safety precautions 8disposal of materials 8electrical safety 8laser safety 10ozone safety 11toner safety 11

trademarks 22

Ooil 588ozone safety 11

Ppaper path 251

test print 251parts, common 587parts catalog

assembly locations 548how to use

description 547

parts catalog (continued)how to use (continued)

grid 546part number 546units 547

parts catalog, how to useasm./index 546

parts location 547PCB locations


print, paper path test 251print quality

defects 34print quality problems 33printer

safety inspection 13printer safety inspection 13Printing Systems Company web page

603problems

intermittent 133random 133

program fixes, obtaining from web 603

Qquick path, locations 361

Rrandom problems or errors 133reference items, safety inspection 13routine tasks 35

Index 789

running test printspaper path 251

Ssafety inspection 12

instructions 12marking actions as completed 13printer 13printer safety inspection 13reference items 13

safety noticesCAUTION 7DANGER 6description 6

safety precautions 8disposal of materials 8electrical safety 8laser safety 10ozone safety 11toner safety 11

sensor locationsduplex 384, 386env. feeder 384, 386printer 384, 386

sensorslocations 384

SIMM 539soap 588solenoid locations

env. feeder 364printer 364

START of CallSee getting started 25

status messages 239switch locations

duplex 384, 386env. feeder 384, 386printer 384, 386

Ttest print, paper path 251test prints, running 251toner safety 11trademarks 22troubleshooting

See getting started 25

Uupdates (code), obtaining from web

603utilities, obtaining from web 603

Wweb page, Printing Systems Company

603wrist band, ESD 20

Index 790

IBMR

Printed in the United States of Americaon recycled paper containing 10%recovered post-consumer fiber.

G544-5514-01