IBMI Infoprint 21
Service Guide
IBM
Note:Before using this information and the product it supports, be sure to read the general informationunder Notices (see “Notices and Safety Information” on page 19).
First Edition (April 2000)
This edition applies to G544-5702-00.
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IBM Printing SystemsDepartment H7FE Building 003GInformation DevelopmentPO Box 1900Boulder CO USA 80301-9191
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© Copyright International Business Machines Corporation 2000. All rights reserved.US Government Users Restricted Rights – Use, duplication or disclosure restricted by GSA ADP Schedule Contract with IBM Corp.
Master Table of ContentsNotices and Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Danger Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Caution Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Attention Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Approved Power Cord and Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Connecting or Disconnecting a Communication Port, a Teleport, or an Attachment Connector . . . . . . . . . 24Disposal of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrostatic Discharge (ESD) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Extension Cords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Laser Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Ozone Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Servicing During an Electrical Storm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Toner Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Printer Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Power-Receptacle Safety-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
About This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Related Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Trademarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 1. Diagnosing Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41MAP 003: End of Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
© Copyright IBM Corp. 2000 3
End of Diagnosing Problems and the Problem Remains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAP 010: Start MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operator Panel Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error Message with Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Coax/Twinax NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Ethernet / Token-Ring NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Electrical Noise / Intermittent Operation (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Excess Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Operator Panel, Controller and Power Problems (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Offset Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Duplex Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Envelope Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Tray 2 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Tray 3 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83MAP 002: Install New Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84MAP 006: Reseat Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86MAP 008: Install New Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87MAP 011: Tray x Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89MAP 012: (Aux/Env) Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97MAP 015: Tray x Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101MAP 016: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 109MAP 017: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 111MAP 031: Unload Paper From Main Output Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113MAP 035: Unload Paper From Offset Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115MAP 041: Install Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116MAP 042: Install Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118MAP 043: Install Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120MAP 049: Close Face-up Output Bin When Duplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
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MAP 074: Close Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125MAP 075: Close Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129MAP 200: Wrong Paper Size - Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131MAP 201: Wrong Paper Size - Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132MAP 220: Paper Jam - Early Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134MAP 221: Paper Jam - Late Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148MAP 230: Paper Jam - Late Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162MAP 232: Paper Jam - Exit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167MAP 250: Paper Jam - Duplex Early Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171MAP 253: Paper Jam - Late Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173MAP 254: Paper Jam - Duplex On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175MAP 255: Paper Jam - Duplex Late Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177MAP 261: Paper Jam - Late Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179MAP 262: Paper Jam - Offset On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182MAP 272: Paper Jam - Exit On (Specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184MAP 275: Paper Jam - Early Exit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190MAP 276: Paper Jam - Exit On (Universal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192MAP 430: Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197MAP 451: Fan Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202MAP 454: Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204MAP 460: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206MAP 511: Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207MAP 623: Data Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209MAP 630: NVM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210MAP 631: NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211MAP 650: Service Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212MAP 651: Boot Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213MAP 652: Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214MAP 653: File Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216MAP 654: HW Error (MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217MAP 661: Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
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MAP 671: Disk Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220MAP 699: HW Error (Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221MAP 714: Duplex Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222MAP 772: ENV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223MAP 795: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225MAP 821: PS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226MAP 831: Controller Loop Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227MAP 851: IPDS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228MAP 852: IPDS Add Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229MAP 853: IPDS Low Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231MAP 854: IPDS Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232MAP 860: No CX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233MAP 861: No TX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234MAP 862: CX Key Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235MAP 872: Network Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236MAP 900: Background or Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237MAP 905: All Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240MAP 910: All Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242MAP 920: Damaged Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245MAP 930: Not Fused or Partially Fused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248MAP 935: Light Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250MAP 940: Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253MAP 941: Repeating Spots or Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256MAP 945: Residual or Ghost Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258MAP 950: Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260MAP 955: Spots on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263MAP 965: Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265MAP 970: Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268MAP 975: Voids on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270MAP 980: Horizontal Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273MAP 985: Vertical Band Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
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Chapter 2. Diagnostic Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278Printer Power-On Sequence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Accessing Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294
Printing the Service Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the CE Laptop PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Chapter 3. Wiring and Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297Master Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . 299Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and to Fan Asm and Front Cover
Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and Fuser Asm . . . . . . . . . . . . . . 301Pin-Out Diagram D: MCU PCB to Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear Cover Interlock Switch . . . . . . . . . 303Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to Paper Low Photo Sensor and Lift
Control Photo Sensor, Pick Clutch, Feed Clutch, and Tray Lift Motor . . . . . . . . . . . . . . . . . . . . 304Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor, and Main Motor . . . . . . . . . 305Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor, Aux Pick-up Solenoid,
Registration Sensor, Registration Clutch, Toner Sensor, and Envelope PCB. . . . . . . . . . . . . . . . . 306Pin-Out Diagram J: MCU PCB to Laser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Chapter 4. Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Major Assemblies, Components, and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312PCBs (Printed Circuit Boards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
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Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Chapter 5. Removals and Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Text and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3255v DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Aux Drive Gear Shaft and Aux Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Aux No Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Aux No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Aux Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Aux Pick Up Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Aux Pick Up Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Aux Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Aux Retard Pad Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Aux Tray Bottom Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Bearing and Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Duplex Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Duplex Connector Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
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Duplex Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353Duplex Face Up Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Duplex Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Duplex Motor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Duplex Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357Duplex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Duplex Roll Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359Duplex Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Duplex Upper Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361ENV Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362ENV Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363ENV Clutch (Electric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364ENV Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366ENV Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367ENV Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368ENV Large Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369ENV No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370ENV No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371ENV Retard Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372ENV Roll Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373ENV Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375ENV Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376ENV Tray Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377ENV Tray Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384Face-Up Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
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Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389Feed Tray Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392Front Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398Fuser Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Harness (J27, J11, J262 - J271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401Harness (J34-P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Left Handle Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410Lift Control Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415Metal Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Middle Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
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Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420Offset Direction Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422Offset Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423Offset Exit Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424Offset Exit Bin Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Offset Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428Offset Inner Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Offset Inner Chute Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Offset Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Offset Mechanism Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Offset PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Offset Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435Offset Tray Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437Option Chute Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440Option Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441Option Gear Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Option Harness (J52-J521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443Option Harness (J53-531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446Option Lift Control Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447Option No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449Option Paper Low Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450Option Paper Size Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451
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Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Option Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459Option Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460Option Top Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463Paper Size Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464Paper Size Housing Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Paper Sizing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466PCB Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Rear Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476Rear Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485Rubber Registration Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Rubber Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489
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Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Tray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494Tray Lift Motor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498Tray Retard Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Chapter 6. Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 504Using the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Approved Cleaners and Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519Assembly 4: 550-Sheet Tray Asm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521Assembly 5: 550-Sheet Tray Asm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523Assembly 6: Paper Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526Assembly 7: Aux Tray Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530Assembly 8: P/H Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533Assembly 9: Chute Transfer and Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536Assembly 10: Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538Assembly 11: Drive and Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541Assembly 12: Frame and Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543Assembly 13: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546Assembly 14: Optional Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549Assembly 15: Optional Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552Assembly 16: Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556
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Assembly 17: Envelope Feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559Assembly 18: Duplex 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562Assembly 19: Duplex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564Assembly 20: Offset Output Bin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Assembly 21: Offset Output Bin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
Parts Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5735 V DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Actuator And Support Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Aux Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Drive Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bearing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Coax NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Compact Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Face-up Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env No-Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Ethernet NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581
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Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Chute Pinch Roll Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Font Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 120 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 230 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Harness (AC - J285) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J1 - J101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J21 - J211, J212, J213) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J22 - J223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J23 - J231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J25 - J251) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J26 - J261) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J27, J11, J262-J271). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591
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Harness (J28 - J281) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J282 - J9, J288 - J9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J31 - J311). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J33 - J331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J34 - J341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J34 - P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J4 - Operator Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J42 - J421) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J43 - J432, J433) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J45 - J451) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J66 - J661, J662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596IBM AFP/IPDS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 120V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 230V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Memory DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Exit Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601
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Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Top Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Rear Cover Asm (With Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Asm (Without Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Token Ring NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612
Master Table of Contents 17
Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Twinax NIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Chapter 7. Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615Periodically Replaced Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Appendix A. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 616
Appendix B. Drivers, Technical Support, and Warranty Information . . . . . . . . . . . . . . . . . . . . . 617Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Dealer Warranty Claim Center (DWCC), U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Maintenance (Service) Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Appendix C. Parts Theory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 620
Master Table of Contents 18
Notices and Safety Information
Safety Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Danger Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Caution Hazard Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Other Caution Symbols Used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Attention Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Approved Power Cord and Receptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Connecting or Disconnecting a Communication Port, a Teleport, or an Attachment Connector . . . . . . . . . 24Disposal of Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrical Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Electrostatic Discharge (ESD) Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Using the ESD Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Extension Cords. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Fire Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Laser Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Ozone Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Servicing During an Electrical Storm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Toner Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Reference Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Printer Safety Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Safety Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Power-Receptacle Safety-Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
© Copyright IBM Corp. 2000 19
References in this publication to IBM products, programs or services do not imply that IBM intends to make theseavailable in all countries in which IBM operates. Any reference to an IBM licensed product, program, or service isnot intended to state or imply that only IBM’s product, program, or service may be used. Any functionallyequivalent product, program, or service that does not infringe any of IBM’s intellectual property rights may be usedinstead of the IBM product. Evaluation and verification of operation in conjunction with other products, exceptthose expressly designated by IBM, is the user’s responsibility.
Any performance data contained in this document was obtained in a controlled environment based on the use ofspecific data. The results that may be obtained in other operating environments may vary significantly. Users ofthis document should verify the applicable data in their specific environment. Therefore, such data does notconstitute a performance guarantee or warranty.
IBM may have patents or pending patent applications covering subject matter in this document. The furnishing ofthis document does not give you any license to these patents. You can send license inquiries, in writing, to theIBM Corporation, IBM Director of Licensing, 208 Harbor Drive, Stamford, Connecticut, United States, 06904.
Notices and Safety Information 20
Safety NoticesThere are two types of safety notices: Danger and Caution.
Danger Hazard LevelThe word Danger indicates the presence of a hazard that has the potential of causing death or serious personalinjury.
DANGER notices are numbered <1-1>, <1-2>, and so forth where they appear in the text of this manual. Use thenotice number to locate the national language translation of that notice in the IBM Infoprint 20/21/32/40: Warranty,Communication Statements, and Safety Information.Example of a Danger notice:
Notices and Safety Information 21
Caution Hazard LevelThe word Caution indicates the presence of a hazard that has the potential of causing moderate or minorpersonal injury.
CAUTION notices are numbered <2-1>, <2-2>, and so forth where they appear in the text of this manual. Use thenotice number to locate the national language translation of that notice in the IBM Infoprint 20/21/32/40: Warranty,Communication Statements, and Safety Information.Example of a Caution notice:
! CAUTION:
<2-23> Pinch hazards exist in this area. hcsf
0223
Other Caution Symbols UsedOther Caution symbols used in this manual include the following:
Laser Safety High Temperature Heavy Weight
Notices and Safety Information 22
Attention NoticesThe word Attention calls attention to the possibility of damage to a program, device, system, or data.
Attention notices are not numbered, or translated in the IBM Infoprint 20/21/32/40: Warranty, CommunicationStatements, and Safety Information.Example of an Attention notice:
Attention: This is an ESD sensitive device (see “Electrostatic Discharge (ESD) Procedures” on page 26).
Notices and Safety Information 23
Safety Precautions
Approved Power Cord and Receptacle
Connecting or Disconnecting a Communication Port, a Teleport, or anAttachment Connector
Notices and Safety Information 24
Disposal of Materials
Electrical SafetyThis printer is inspected and listed by recognized national testing laboratories, such as Underwriters Laboratories,Inc. (UL) in the U.S.A. and Canadian Standards Association (CSA) in Canada. Listing of a product by a nationaltesting laboratory indicates that the product is designed and manufactured in accordance with nationalrequirements intended to minimize safety hazards. IBM equipment meets a very high standard of safety in designand manufacture. Remember, however, that this product operates under conditions of high electrical potentialsand heat generation, both of which are functionally necessary.
Notices and Safety Information 25
Electrostatic Discharge (ESD) ProceduresRead the following electrostatic discharge (ESD) information because, if discharged into the circuitry of anintegrated circuit, static electricity can damage the circuit.
The following Attention notice in the text of this book warns of possible damage caused by ESD.
Attention:
This is an ESD sensitive area.
Follow these guidelines to prevent damage to ESD-sensitive components:v Make the fewest possible movements to minimize static electricity. Static electricity is more likely in a low
humidity environment.v Keep an ESD-sensitive part in its original shipping container, usually a protective bag, until you are ready to
install it.v Touch the metal frame of the printer or assembly to discharge static electricity in your body just before touching
the ESD-sensitive part.v Hold the ESD-sensitive part by its edges. Do not touch any components, pins, or connectors. If possible, keep
one hand on the frame while you are installing or removing an ESD-sensitive part.v Do not place an ESD-sensitive part on anything that can provide a discharge path from your body through the
ESD-sensitive part. If you need to put down the ESD-sensitive part, put it into the ESD protective wrapper inwhich it was shipped.
v Cables may connect to logic cards or boards that are ESD-sensitive. Be careful when working with connectors.v Prevent ESD-sensitive parts from being touched by other persons.
Continue to “Using the ESD Kit” on page 27.
Notices and Safety Information 26
Using the ESD KitTo safely discharge all static electricity, use the ESD kit following the guidelines under “Electrostatic Discharge(ESD) Procedures” on page 26.v Turn off the printer before you put on the ESD wrist band.v Connect the wrist band to an unpainted, frame-ground point of the printer.v Remove the ESD wrist band when working on any part of the printer that has power turned on.v Do not put the ESD mat near any electrical circuit that has power turned on. The internal resistance (1
megohm) in the ESD cable limits the current if it touches a high voltage.v Do not put the ESD mat near a grounded surface. Ground the ESD mat only through the ESD cable. The ESD
cable supplies a high resistance to ground for your safety. If the ESD mat touches a grounded surface, the highresistance in the ESD cable is bypassed, which causes the ESD mat not to work as expected.
Extension Cords
Fire SafetyBecause the paper and toner used in the printer can burn, you should take normal precautions to prevent fire.These precautions include common sense measures, such as keeping potentially combustible materials (forexample, curtains and chemicals) away from the printer, providing adequate ventilation and cooling, limitingunattended operation, and having trained personnel available and assigned to the printer.
Notices and Safety Information 27
Laser Safety
CAUTION:<2-21> Do not disassemble or attempt to adjust the laser unit. Do not attempt to operate the laser outside of theprinter.
This printer complies with the performance standards set the by U.S. Food and Drug Administration for a Class 1Laser Product. This means that the printer belongs to a class of laser products that does not produce hazardouslaser radiation in a customer access area. This classification was accomplished by providing the necessaryprotective housing and scanning safeguard to ensure that laser radiation is inaccessible or within Class 1 limits.
There are various tool-operated machine covers that should be moved, removed or replaced only by trainedservice personnel. There are no operator controls or adjustments associated with the laser.
No operator maintenance is required to keep the product in compliance as a Class 1 Laser Product.
No adjustments that affect laser operation or power are accessible to the operator.
Ozone SafetyAn infinitesimal amount of ozone gas (O₃) is generated during corona discharge from the transfer charge roller.The ozone gas is emitted only when the printer is operating. This printer meets the ozone emission referencevalue set by Underwriters Laboratory (UL) at the time it is shipped from the factory.
Notices and Safety Information 28
Servicing During an Electrical Storm
Toner Safety
! CAUTION:
<2-38> To vacuum toner, use only a vacuum cleaner that IBM hasapproved for use with toner.
hcsf
0238
Toner is a non-poisonous substance composed of minute, plastic components. If toner adheres to your skin or toyour clothes, remove as much as possible with a dry tissue, then wash with cold water. If you use hot water, thetoner will gel and become difficult to remove. Avoid letting toner come into contact with vinyl. The plasticizers invinyl can also plasticize some toners.
Notices and Safety Information 29
Safety InspectionSee “Danger Hazard Level” on page 21 and “Caution Hazard Level” on page 22 for an explanation of Danger andCaution notices.
InstructionsPerform this safety inspection before performing any of the following tasks:v Accept a machine for service agreementv Provide per-call servicev Relocate a machinev Review changes or attachments on any IBM machine that is leased, on service agreement, or on per-call
service
Ensure that you correct unsafe conditions before you continue.
Possible safety hazards are:v Electrical —An electrically charged frame, or exposed wires or connections, can cause serious electrical shock.v Mechanical —A missing safety cover or shield is hazardous. Moving parts, such as gears, shaft, and pulleys
are hazardous.v Chemical —Use only approved cleaning agents. Do not use other solvents or chemicals.
Reference ItemsYou will need the following items:v A copy of the machine EC historyv Electrical Safety for IBM Customer Engineers, S229-8124
Notices and Safety Information 30
Printer Safety Inspection
1. Perform the “Power-Receptacle Safety-Check” on page 34.2. Ensure that the correct power cord is used.3. Ensure that all attaching cables are disconnected from the printer.4. Inspect the power cord for wear or damage.5. Ensure that the machine is steady.6. Remove all covers and access panels (see Covers under ″Removals and Replacements″).7. Inspect the covers and access panels for damage.8. Ensure that all warning labels are in place.9. If you are placing this printer on service contract with IBM, check for changes not made by IBM. If you find
changes not made by IBM, get the R009 Non-IBM Alterations/Attachments Survey form from the IBM branchoffice. Complete the form and return it to the branch office.
10. Ensure that all ground connectors are correctly connected (see “Safety Ground” on page 33).11. Measure the resistance from the ground pin of the printer power cord connector to the printer frame. The
reading must not exceed 0.1 ohms.12. Perform a visual inspection of all cables, connections, and plugs for worn or damaged wiring.
Notices and Safety Information 31
13. Check for signs of contamination, corrosion, smoke, or burning. If there are signs of smoke or burning, checkthe Maintenance Agreement Qualification (MAQ) form for the correct repair procedure, if needed.
14. Install all covers and access panels that were removed.
Notices and Safety Information 32
Safety Ground
HA
K30
8Figure 1. Safety Ground
Notices and Safety Information 33
Power-Receptacle Safety-CheckSee Electrical Safety for IBM Customer Engineers, S229-8124, for the correct test equipment and proceduresbefore performing any of the following tasks. ( Electrical Safety for IBM Customer Engineers, S229-8124 may notbe applicable for other countries):
v Checking ac voltage at the power receptaclev Checking ac impedance to ground at the power receptacle
Perform the power receptacle safety check as described in Electrical Safety for IBM Customer Engineers,S229-8124. Use only the applicable high-voltage probes.Table 1. Nominal Power Receptacle AC Voltage (110–120 V AC, 50–60 Hertz)
Machine Rating(50–60 Hertz) Minimum Voltage Maximum Voltage
100-127 V ac 90 V ac 140 V ac
220–240 V ac 200 V ac 264 V ac
Do not continue until the voltages are in the correct range.
Notices and Safety Information 34
About This Book
This book describes how to diagnose and repair the Infoprint 21.
Related PublicationsTo obtain additional copies of this book or of any related publication, contact your IBM service representative, yourauthorized service dealer, or, in the U.S.A. or Canada, call 1-800-879-2755.
For related topics not covered in this book, refer to the list below.v IBM Infoprint 20/21/32/40: Warranty, Communication Statements, and Safety Information, G544-5523v IBM Infoprint Printers: Service CDROM, GK2T-9300v Infoprint 21 User’s Guide, G544-5701v Infoprint 21 Quick Reference Card, G544-5700v Infoprint 21 Setup Poster, S544-5699v Ethernet and Token Ring Configuration Guide, S544-5711v Twinax and Coax Configuration Guide, S544-5712v IPDS and SCS Technical Reference, S544-5312
© Copyright IBM Corp. 2000 35
TrademarksThe following terms are trademarks of the IBM Corporation in the United States or other countries or both:
IBM®
Infoprint™
Microsoft, Windows, Windows NT, and the Windows logo are trademarks of Microsoft Corporation in the UnitedStates and/or other countries.
Other company, product, or service names may be the trademarks or service marks of others.
About This Book 36
Chapter 1. Diagnosing Problems
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41MAP 003: End of Call . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
End of Diagnosing Problems and the Problem Remains . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43MAP 010: Start MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Defining the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Solving the Problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Operator Panel Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48Error Message with Error Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Print Quality Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Coax/Twinax NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Ethernet / Token-Ring NIC Printing Problem (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Electrical Noise / Intermittent Operation (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Excess Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Operator Panel, Controller and Power Problems (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Offset Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Duplex Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Envelope Not Recognized (Printer) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Tray 2 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Tray 3 Not Recognized (Printer). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83MAP 002: Install New Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84MAP 006: Reseat Toner Cartridge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86MAP 008: Install New Fuser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87MAP 011: Tray x Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89MAP 012: (Aux/Env) Empty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97MAP 015: Tray x Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101MAP 016: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 109MAP 017: Adjust Guides For Paper Size Or Set Size In Menu . . . . . . . . . . . . . . . . . . . . . . . . . 111MAP 031: Unload Paper From Main Output Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
© Copyright IBM Corp. 2000 37
MAP 035: Unload Paper From Offset Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115MAP 041: Install Tray 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116MAP 042: Install Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118MAP 043: Install Tray 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120MAP 049: Close Face-up Output Bin When Duplexing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122MAP 074: Close Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125MAP 075: Close Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129MAP 200: Wrong Paper Size - Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131MAP 201: Wrong Paper Size - Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132MAP 220: Paper Jam - Early Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134MAP 221: Paper Jam - Late Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148MAP 230: Paper Jam - Late Exit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162MAP 232: Paper Jam - Exit On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167MAP 250: Paper Jam - Duplex Early Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171MAP 253: Paper Jam - Late Duplex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173MAP 254: Paper Jam - Duplex On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175MAP 255: Paper Jam - Duplex Late Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177MAP 261: Paper Jam - Late Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179MAP 262: Paper Jam - Offset On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182MAP 272: Paper Jam - Exit On (Specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184MAP 275: Paper Jam - Early Exit Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190MAP 276: Paper Jam - Exit On (Universal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192MAP 430: Motor Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197MAP 451: Fan Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202MAP 454: Fuser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204MAP 460: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206MAP 511: Laser Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207MAP 623: Data Error. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209MAP 630: NVM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210MAP 631: NVRAM Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211MAP 650: Service Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Chapter 1. Diagnosing Problems 38
MAP 651: Boot Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213MAP 652: Memory Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214MAP 653: File Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216MAP 654: HW Error (MCU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217MAP 661: Firmware Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219MAP 671: Disk Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220MAP 699: HW Error (Offset) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221MAP 714: Duplex Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222MAP 772: ENV Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223MAP 795: Offset Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225MAP 821: PS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226MAP 831: Controller Loop Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227MAP 851: IPDS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228MAP 852: IPDS Add Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229MAP 853: IPDS Low Mem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231MAP 854: IPDS Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232MAP 860: No CX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233MAP 861: No TX Host Sync . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234MAP 862: CX Key Request . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235MAP 872: Network Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236MAP 900: Background or Dark Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237MAP 905: All Black Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240MAP 910: All Blank Print . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242MAP 920: Damaged Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245MAP 930: Not Fused or Partially Fused Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248MAP 935: Light Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250MAP 940: Image Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253MAP 941: Repeating Spots or Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 256MAP 945: Residual or Ghost Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258MAP 950: Skewed Image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260MAP 955: Spots on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
Chapter 1. Diagnosing Problems 39
MAP 965: Horizontal Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265MAP 970: Vertical Streaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268MAP 975: Voids on Prints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270MAP 980: Horizontal Voids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273MAP 985: Vertical Band Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Chapter 1. Diagnosing Problems 40
IntroductionThis chapter helps you define the problem and begin problem isolation. All problem definition and resolutionbegins in “MAP 010: Start MAP” on page 44. After a problem has been fixed go to “MAP 003: End of Call” onpage 42 to perform the defined procedures prior to completing the call.
If the suggested diagnostics do not resolve the problem, return to “MAP 010: Start MAP” on page 44 and definethe problem again or call for technical support. See “Appendix B. Drivers, Technical Support, and WarrantyInformation” on page 617.
This chapter contains only MAPs (Maintenance Analysis Procedures) for problem diagnosis. Some of theseprocedures require other actions such as printing a Service Page or other checks. “Chapter 3. Wiring and Pin-OutDiagrams” on page 297 contains information on printing test prints and performing checks and tests.
Chapter 1. Diagnosing Problems 41
MAP 003: End of CallUse the following procedure to complete all service calls on the Infoprint 21.1. Ensure the following:v All internal cables and connectors are properly connected.v All covers, doors, panels and paper trays are in place.v Any workstation or network cable is connected.v All power cords are connected.
2. Power on the printer and ensure that the printer performs the correct power-on sequence. See “PrinterPower-On Sequence Check” on page 279.
3. Print a Printer Configuration page to ensure high-quality output. See “Printing the Service Page” on page 295.Look at the Page Count item located on the Printer Configuration page. You may need this count for youractivity reporting.
4. Have the operator print a job to ensure the printer is working correctly.5. Clean the work area.6. Clean the printer covers with a dry cleaning cloth. If necessary, use water and a mild detergent
(non-ammonia).7. Return the printer operation to the operator.
Chapter 1. Diagnosing Problems 42
End of Diagnosing Problems and the Problem RemainsIf the printer has not been fixed using the MAP procedures that you were directed to perform, return to “MAP 010:Start MAP” on page 44. Ensure that you have correctly interpreted the available information and define theproblem again.
Review all MAPs that you were directed to. If you suspect an intermittent problem, check the following:v All connectors and wiring associated with the suspected FRUs.v All frame grounds and ground connectors.v If you suspect a consumable (CRU), supplies or supplies storage problem (environmental conditions such as
temperature, humidity, or ventilation), refer to the IBM Infoprint 21 User’s Guide.
Refer to the list of Suspect FRUs at the beginning of the MAP and repair/replace any remaining FRUs that youhave not already replaced. After each replacement, print a Printer Configuration page to determine if the problemhas been fixed. If you have replaced a part that did not correct the problem, reinstall the original part beforecontinuing.
If a fix has not been found for the problem, contact your next level of support. See “Appendix B. Drivers, TechnicalSupport, and Warranty Information” on page 617.
Chapter 1. Diagnosing Problems 43
MAP 010: Start MAP
Defining the ProblemUse the following suggestions to gather the information to accurately define the printer problem, and then go to“Solving the Problem” on page 46.1. Discuss the problem with the operator. Note information such as error messages, other symptoms (such as
print quality), what happened, what type of print job, and other recent problems or changes. Review the printerhistory with the operator and obtain or print a Printer Configuration page and an Error Log (see “Printing theService Page” on page 295).
2. Power on the printer. The printer performs start-up diagnostic routines that check the printer controller and theprinter. Most printer failures that occur during this start-up diagnostic portion of the initialization process, resultin either an error code or a message posted immediately on the operator panel. See “Printer Power-OnSequence Check” on page 279 for the correct sequence of events when the printer is powered on.
3. Observe the display on the operator panel.
Note: All Operator Panel messages referenced in this service guide are in English. If your Operator Panel hasbeen set to a language other than English, you may want to change the language to English by usingthe Language Menu . See the Infoprint 21 User’s Guide.
v Is information correctly displayed?v Is the display blank after power is switched on?v Does INFOPRINT 21 INITIALIZING display?v Does READY display?v Do you have an error code or message?
4. Try to duplicate the failure by printing a Printer Configuration page (see “Printing the Service Page” onpage 295) or by printing the customer job and noting the following:v Printer fails to print a test print when not connected to a workstation or a network.v Printer fails when connected to a workstation or network.v Printer prints, but the paper jams.
Chapter 1. Diagnosing Problems 44
v Printer prints, but has poor quality.5. See “Solving the Problem” on page 46.
Chapter 1. Diagnosing Problems 45
Solving the ProblemUsing the problem information that you have gathered (see “Defining the Problem” on page 44, go to Table 2.Select the Symptom or the Indication that best describes the printer problem, and then go to the suggested itemto further isolate the failure. Upon completing the problem diagnosis and repair, go to “MAP 003: End of Call” onpage 42 to complete the call.Table 2. Diagnostic Quick Path
Symptom Indication Go To...
Operator PanelProblem Indications
Solid black rectangle boxes always on “Operator Panel, Controller and Power Problems(Printer)” on page 73
Message with error code “Error Message with Error Code” on page 55
Message without error code “Operator Panel Messages” on page 48
Blank, push button or other display problem “Operator Panel, Controller and Power Problems(Printer)” on page 73
Print Quality Print quality problem Table 5 on page 59
Feature Problems Ethernet or token ring problems “Ethernet / Token-Ring NIC Printing Problem(Printer)” on page 63
Twinax or coax problems “Coax/Twinax NIC Printing Problem (Printer)” onpage 60
Duplex not working / not recognized “MAP 714: Duplex Error” on page 222
Envelope Feeder not working / not recognized “MAP 772: ENV Error” on page 223
Offset Output Bin not working / not recognized “MAP 795: Offset Error” on page 225
Tray 2 not working / not recognized “Tray 2 Not Recognized (Printer)” on page 81
Tray 3 not working / not recognized “Tray 3 Not Recognized (Printer)” on page 83
Memory problems (Memory error) “MAP 652: Memory Error” on page 214
Table continues on p. 47.
Chapter 1. Diagnosing Problems 46
Table 2. Diagnostic Quick Path (continued)
Symptom Indication Go To...
Other Problems Power “Operator Panel, Controller and Power Problems(Printer)” on page 73
Excessive Noise “Excess Noise” on page 69
Electrical Noise, Intermittent Operation (Printer) “Electrical Noise / Intermittent Operation (Printer)” onpage 66
Chapter 1. Diagnosing Problems 47
Operator Panel MessagesThe Operator Panel messages in the following table are listed in alphabetical order in English. If your OperatorPanel has been set to a language other than English you may want to change the language to English by usingthe Language Menu (see Infoprint 21 User’s Guide).
Select the message that was displayed in the Operator Panel display area, then perform the specified action.Table 3. Operator Panel Messages
Message Meaning Action
CANCEL PRINT JOB? / +YES, - NO
A job was printing when the printer went offline. Thismessage allows the operator to cancel or pause the job.
Press the + key to cancel the job, press the− key to pause the job and take the printeroffline.
CANCELING JOB The printer is canceling a PCL or PostScript job. None required.
CLEAN DISK? / + YES, -NO
You selected the CLEAN DISK action on the ResetMenu.
Press the + key to clean the hard drive.Cleaning the hard drive removes all filesother than those that contain IPDS fonts.Press the − key to continue withoutformatting.
CLEAN CANCELED Cleaning was canceled. None required.
COLD RESET / PLEASEWAIT
The printer is powering up and resetting all menu valuesto the factory defaults.
None required; however, you need torestore any unique settings for the printer(such as default trays or bins).
CX/TX CANCEL SENT A coax or twinax cancel request was sent to the host. None required.
CX/TX INVALID KEY An invalid coax or twinax key was pressed. None required.
DEFAULT A4 / PLEASEWAIT
The printer is powering up and setting the A4 papergroup as the default.
None required.
DEFAULT LETTER /PLEASE WAIT
The printer is powering up and setting the LETTERpaper group as the default.
None required.
FORMAT COMPLETE Formatting is finished. None required.
Chapter 1. Diagnosing Problems 48
Table 3. Operator Panel Messages (continued)
Message Meaning Action
FORMAT FLASH? / + YES,- NO
You selected the FORMAT FLASH action on the ResetMenu.
Press the + key to format the ResourceFlash Memory Module. Press the − key tocontinue without formatting.
FORMAT IGNORED Formatting was canceled. None required.
FORMATTING The printer is formatting the Resource Flash MemoryModule.
None required. Do not power off untilformatting is complete.
INITIALIZING / PLEASEWAIT
The printer is warming up. None required.
IR SENT TO HOST /PRESS ENTER
An interrupt request was sent to the host. Press Enter to continue.
JOB QUEUED An informational page has been submitted from the TestMenu (for example, a configuration page or a fonts list).
None required.
LOAD <dimensions><media type> IN <tray>CUSTOM SIZE NOTDEFINED
A job has requested an unknown paper size. Themessage identifies the media dimensions, media type,and tray, that the print job requested.
Do one of the following:v To print the job on the requested tray,
regardless of what media is in the tray,press Enter .
v To define a custom form that matches thejob, do the following:1. Use the Custom Forms Menu to
define the form.2. Use the Paper Menu to set the tray
size to the new form and the traytype to requested type.
Chapter 1. Diagnosing Problems 49
Table 3. Operator Panel Messages (continued)
Message Meaning Action
LOAD <size> <dimensions><media type> in <tray>
Someone changed the paper in a tray after a job beganformatting. The specified tray no longer contains themedia requested by a job that has already beenformatted. The message identifies the media dimensions(for custom size jobs), the media type, and the tray thatthe print job requested.
Do one of the following:v Reload the tray with the required media.v To print the job from another tray that
contains the correct size media, althoughnot necessarily the correct type, pressEnter .
v Press the Online key and, whenprompted, cancel the job.
LOAD <size> <dimensions><media type> in <tray> /PRESS ENTER TO USEDEFAULT TRAY
The specified tray does not contain the media requestedby a job. The message identifies the media dimensions(for custom size jobs), the media type, and the tray thatthe print job requested.
Do one of the following:v Reload the tray with the required media.
If you reload the auxiliary tray or theenvelope feeder, the printer will set theAUXSIZE or ENVSIZE values to the sizeof the new media.
v To reformat and print the job using thespecified tray, regardless of the media itcontains, press Enter .
v Press the Online key and, whenprompted, cancel the job.
MANUALLY FEED <size><dimensions> <type> INAUX TRAY
Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and the printer is waiting for you to pressthe Enter key to print the next page. The messageidentifies the required media dimensions (for custom sizejobs), the media size (as defined by the AUXSIZE item inthe Paper Menu), and the media type (as defined by theAUX TYPE item in the Paper Menu).
Load the requested media in the auxiliarytray and press the Enter key to print thenext page.
Chapter 1. Diagnosing Problems 50
Table 3. Operator Panel Messages (continued)
Message Meaning Action
MANUALLY FEED<dimensions> <type> INAUX TRAY CUSTOM SIZENOT DEFINED
Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and a job has requested an unknownpaper size. The message identifies the mediadimensions and the media type that the print jobrequested.
Do one of the following:v To print the job on the requested tray,
regardless of what media is in the tray,press Enter .
v To define a custom form that matches thejob, do the following:1. Use the Custom Forms Menu to
define the form.2. Use the Paper Menu to set the tray
size to the new form and the traytype to requested type.
MANUAL FEED <size><type> IN AUX TRAY
Manual mode (MANUAL=ON) has been selected for theauxiliary tray, and the printer is waiting for you to pressthe Enter key to print the next page.
Load the requested media in the auxiliarytray and press the Enter key to print thenext page.
MENUS LOCKED /PLEASE WAIT
The system administrator has locked the menu. You canview menu settings but you cannot change them.
None required.
MENUS UNLOCKED /PLEASE WAIT
The system administrator has unlocked the menus. None required. Wait until the messageclears to change menu settings.
NEW VALUES AT NEXTBOUNDARY
You have changed a menu item, but the new value willnot take effect until the next “job boundary”. Differentdata streams, in particular SCS, define job boundaries indifferent ways, so it may take awhile for the new value totake effect.
None required. If problems occur, makesure you change menu values only when nojobs are printing (the printer is in Readystate).
NO CX HOST SYNC /PRESS ENTER
There is no host synchronization over the coax port. Press Enter to continue.
NO TX HOST SYNC /PRESS ENTER
There is no host synchronization over the twinax port. Press Enter to continue.
Chapter 1. Diagnosing Problems 51
Table 3. Operator Panel Messages (continued)
Message Meaning Action
OFFLINE The printer is offline. Press the Online key to make the printeractive.
OFFLINE IN PROGRESS The printer is going offline. None required.
ONLINE IN PROGRESS The printer is going online. None required.
ONLINE HEX PRINT The printer is performing a hexadecimal dump. None required.
PA1 KEY SENT A PA1 request was sent to the host over the coaxinterface.
None required.
PA2 KEY SENT A PA2 request was sent to the host over the coaxinterface.
None required.
PA KEY REQUESTED /PRESS ENTER
A PA1 or PA2 request was sent to the host over the coaxinterface.
Press Enter to continue.
POWER SAVE ON The printer is in power-saving mode and has temporarilyshut off power to certain of its components. Power will berestored as soon as a job is submitted.
None required.
PRESS ENTER TO PRINTPARTIAL PAGE
A PCL job has left the last page of a job in the printerbuffer.
Press Enter to print the page.
PRESS ONLINE TO PRINT An informational page (for example, a printerconfiguration page) has been queued for printing,however, the printer is offline.
Press Online to put the printer online andprint the job.
PRINTING jobname The printer is printing a job. None required.
PRINTING IPDS / FROMTRAY x
The printer is printing an IPDS job using paper from thespecified tray.
None required.
PRINTING IPDS / COPY xof x
The printer is printing an IPDS job. None required.
PRINTING PCL / FROMTRAY x
The printer is printing a PCL job using paper from thespecified tray.
None required.
Chapter 1. Diagnosing Problems 52
Table 3. Operator Panel Messages (continued)
Message Meaning Action
PRINTING PCL / COPY x ofx
The printer is printing a PCL job. None required.
PRINTING PS / FROMTRAY x
The printer is printing a PostScript or PDF job usingpaper from the specified tray.
None required.
PRINTING PS / COPY x ofx
The printer is printing a PostScript or PDF job. None required.
PROCESSING jobname The printer is processing a job. None required.
PROCESSING IPDS The printer is processing an IPDS job. None required.
PROCESSING PCL The printer is processing a PCL job. None required.
PROCESSING PS The printer is processing an PostScript or PDF job. None required.
READ ONLY VALUE You cannot change the menu value displayed on theoperator panel.
None required.
READY The printer is ready to receive data. None required.
REBOOT THE PRINTER? /+ YES, - NO
You have changed a menu item that cannot take effectuntil the printer is rebooted. This message lets you verifythat you want to reboot the printer.
Press the + key to reboot. Press − tocontinue operating with the old values untilthe next time the printer is rebooted.
REBOOTING / PLEASEWAIT
The printer is rebooting. None required.
RESET COMPLETE The toner or fuser counter has been reset to 0. None required.
REQUEST RECEIVED A user powered-on the printer while holding down keyson the operator panel. For example, holding down theOnline key while powering on the printer resets printervalues to their factory defaults.
The printer recognizes the special requestand the user can let go of the keys.
RESET COUNTER? / +YES, - NO
You asked to reset the toner counter or the fusercounter.
Press the + to reset the counter. Press the− key to cancel the reset.
Chapter 1. Diagnosing Problems 53
Table 3. Operator Panel Messages (continued)
Message Meaning Action
RESET IGNORED A request to reset the toner or fuser counter wascanceled; the counter has not been reset.
None required.
RESET TO FACTORYDEFAULTS? / + YES, - NO
You asked to reset printer values to the factory defaults. Press the + key to reset the values. Pressthe − key to continue without resetting.
RESETTING... The toner or fuser counters are being reset. None required.
RESTORING DEFAULTS The printer is restoring the factory defaults for the printeror network interface card.
None required.
WARMING UP The printer is warming up. When it is warm, it displaysthe READY message.
None required. If the message seems toappear too frequently, change the value forthe power-saving mode to a larger value.
Chapter 1. Diagnosing Problems 54
Error Message with Error CodeThe Operator Panel messages in the following table are listed in numerical order by error code. Note thatmessages contain two lines. The error code appears on the second line. Find the error code that was displayedon the Operator Panel, then go to the suggested MAP to further isolate the failure.Table 4. Error Message with Error Code
Error Code Go To...
002 TONER LOW / INSTALL NEW TONER CARTRIDGE “MAP 002: Install New Toner Cartridge” on page 84
006 TONER ERROR / RESEAT TONER CARTRIDGE “MAP 006: Reseat Toner Cartridge” on page 86
011 TRAY <tray> EMPTY / LOAD <size> <dimensions> <mediatype>
“MAP 011: Tray x Empty” on page 89
012 AUX/ENV EMPTY / LOAD <size> <dimensions> <mediatype>
“MAP 012: (Aux/Env) Empty” on page 97
016 CHECK TRAY <tray> / ADJUST GUIDES FOR PAPER SIZEOR SET SIZE IN MENU
“MAP 016: Adjust Guides For Paper Size Or Set Size In Menu”on page 109
031 OUTPUT FULL / UNLOAD PAPER FROM MAIN BIN “MAP 031: Unload Paper From Main Output Bin” on page 113
035 OUTPUT FULL / UNLOAD PAPER FROM OFFSET BIN “MAP 035: Unload Paper From Offset Bin” on page 115
041 TRAY MISSING / INSTALL TRAY 1 “MAP 041: Install Tray 1” on page 116
042 TRAY MISSING / INSTALL TRAY 2 “MAP 042: Install Tray 2” on page 118
043 TRAY MISSING / INSTALL TRAY 3 “MAP 043: Install Tray 3” on page 120
049 COVER OPEN / CLOSE FACEUP BIN WHEN DUPLEXING “MAP 049: Close Face-up Output Bin When Duplexing” onpage 122
074 COVER OPEN / CLOSE FRONT COVER “MAP 074: Close Front Cover” on page 125
075 COVER OPEN / CLOSE REAR COVER “MAP 075: Close Rear Cover” on page 129
200 DUPLEX ERROR / WRONG PAPER SIZE “MAP 200: Wrong Paper Size - Duplex” on page 131
201 TRAY <tray> ERROR / WRONG PAPER SIZE “MAP 201: Wrong Paper Size - Tray” on page 132
Chapter 1. Diagnosing Problems 55
Table 4. Error Message with Error Code (continued)
Error Code Go To...
220 PAPER JAM / OPEN FRONT COVER “MAP 220: Paper Jam - Early Feed” on page 134
221 PAPER JAM / CHECK PAPER TRAY AND OPEN FRONTCOVER
“MAP 221: Paper Jam - Late Feed” on page 148
230 PAPER JAM / OPEN FRONT COVER AND REAR COVERS “MAP 230: Paper Jam - Late Exit” on page 162
232 PAPER JAM / OPEN REAR COVER “MAP 232: Paper Jam - Exit On” on page 167
250 PAPER JAM / CHECK DUPLEX AREA “MAP 250: Paper Jam - Duplex Early Registration” on page 171
253 PAPER JAM / CHECK DUPLEX AREA “MAP 253: Paper Jam - Late Duplex” on page 173
254 PAPER JAM / CHECK DUPLEX AREA “MAP 254: Paper Jam - Duplex On” on page 175
255 PAPER JAM / CHECK DUPLEX AREA “MAP 255: Paper Jam - Duplex Late Registration” on page 177
261 PAPER JAM / OPEN OFFSET BIN REAR COVER “MAP 261: Paper Jam - Late Offset” on page 179
262 PAPER JAM / OPEN OFFSET BIN REAR COVER “MAP 262: Paper Jam - Offset On” on page 182
272 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 272: Paper Jam - Exit On (Specific)” on page 184
275 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 275: Paper Jam - Early Exit Off” on page 190
276 PAPER JAM / OPEN FRONT AND REAR COVERS “MAP 276: Paper Jam - Exit On (Universal)” on page 192
430 MOTOR ERROR / POWER OFF/ON “MAP 430: Motor Error” on page 197
451 FAN ERROR / POWER OFF/ON “MAP 451: Fan Error” on page 202
454 FUSER ERROR / POWER OFF/ON “MAP 454: Fuser Error” on page 204
460 OFFSET ERROR / POWER OFF/ON “MAP 460: Offset Error” on page 206
511 LASER ERROR / POWER OFF/ON “MAP 511: Laser Error” on page 207
623 DATA ERROR / PRESS ENTER TO CONTINUE “MAP 623: Data Error” on page 209
630 NVM ERROR / POWER OFF/ON “MAP 630: NVM Error” on page 210
631 NVRAM ERROR / PARAMETERS RESET / PRESS ENTER “MAP 631: NVRAM Error” on page 211
Chapter 1. Diagnosing Problems 56
Table 4. Error Message with Error Code (continued)
Error Code Go To...
650 SERVICE PORT / CALL SERVICE “MAP 650: Service Error” on page 212
651 HW ERROR / CALL SERVICE “MAP 651: Boot Error” on page 213
652 HW ERROR / CALL SERVICE “MAP 652: Memory Error” on page 214
653 HW ERROR / POWER OFF/ON “MAP 653: File Error” on page 216
654 HW ERROR / POWER OFF/ON “MAP 654: HW Error (MCU)” on page 217
661 CODE ERROR / PRESS ENTER nnn “MAP 661: Firmware Error” on page 219
671 DISK ERROR / CALL FOR SERVICE “MAP 671: Disk Error” on page 220
699 HW ERROR / POWER OFF/ON “MAP 699: HW Error (Offset)” on page 221
714 DUPLEX ERROR / RESEAT DUPLEX “MAP 714: Duplex Error” on page 222
772 ENV ERROR / RESEAT ENV TRAY “MAP 772: ENV Error” on page 223
795 OFFSET ERROR / RESEAT OFFSET BIN “MAP 795: Offset Error” on page 225
821 PS OPTION / RESEAT PS CF “MAP 821: PS Option” on page 226
831 ERROR nnnnn / CALL SERVICE “MAP 831: Controller Loop Trap” on page 227
851 IPDS OPTION / RESEAT IPDS CF “MAP 851: IPDS Option” on page 228
852 IPDS ADD MEM / POWER OFF/ON “MAP 852: IPDS Add Mem” on page 229
853 IPDS LOW MEM / POWER OFF/ON “MAP 853: IPDS Low Mem” on page 231
854 IPDS ERROR / RESET IPDS FONTS “MAP 854: IPDS Error” on page 232
860 NO HOST SYNC / PRESS ENTER “MAP 860: No CX Host Sync” on page 233
861 NO HOST SYNC / PRESS ENTER “MAP 861: No TX Host Sync” on page 234
862 SEND STATE / PRESS ENTER TO SEND PA1 “MAP 862: CX Key Request” on page 235
872 NETWORK OPT / RESEAT OPTION “MAP 872: Network Option” on page 236
Chapter 1. Diagnosing Problems 57
Print Quality ProblemsLink to -- Table 5 on page 59
Before analyzing print quality (PQ) problems, verify that supply items (toner cartridge, bias transfer roll, and fuser)don’t need replacing. Also, check the items listed below.
The quality of the printed image depends upon many factors, some of which are controlled by the customer. Thefollowing customer-controlled items should be as described in the Infoprint 21 User’s Guide:v Toner Cartridgev Paper, envelopes, or transparenciesv Fuserv Bias transfer rollv Stable operating environment
– Temperature– Humidity
v Location– On a level surface– Proper ventilation– Shielded from direct sunlight– Low dust content in air– Not near wall outlets, steamers, electric heaters, volatile gasses, or open flame
v Supplies storage– At the warehouse– In the printer operating environment
Chapter 1. Diagnosing Problems 58
Find the symptom, and then go to the suggested procedure.Table 5. Print Quality Problems
Symptom Go To...
Background “MAP 900: Background or Dark Image” on page 237
Black image “MAP 905: All Black Print” on page 240
Blank image “MAP 910: All Blank Print” on page 242
Damaged page “MAP 920: Damaged Page” on page 245
Dark image “MAP 900: Background or Dark Image” on page 237
Fusing “MAP 930: Not Fused or Partially Fused Image” on page 248
Light (under-toned) image “MAP 935: Light Image” on page 250
Registration of image “MAP 940: Image Registration” on page 253
Repeating (cyclical) spots or voids “MAP 941: Repeating Spots or Voids” on page 256
Residual image or ghosting “MAP 945: Residual or Ghost Images” on page 258
Skewed image “MAP 950: Skewed Image” on page 260
Spots “MAP 955: Spots on Prints” on page 263
Streaks, horizontal “MAP 965: Horizontal Streaks” on page 265
Streaks, vertical “MAP 970: Vertical Streaks” on page 268
Voids “MAP 975: Voids on Prints” on page 270
Voids, horizontal band “MAP 980: Horizontal Voids” on page 273
Voids, vertical band “MAP 985: Vertical Band Voids” on page 276
Chapter 1. Diagnosing Problems 59
Coax/Twinax NIC Printing Problem (Printer)Symptom Explanation Suspected FRUs/Causes Probability
The printer is having problems printing with the Coax/TwinaxNIC.
Coax NIC 40%
Twinax NIC 40%
IBM AFP/IPDS Module 10%
Compact Flash 5%
Controller PCB 5%
Table 6. Coax/Twinax NIC Printing Problem (Printer)
Step Questions/Actions Yes No
1. Is the problem only with IPDS jobs? Go to step 2. Go to step 3.
2. Check the IPDS Status:a. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is IPDS indicated on the Service Page?
Verify that there is enoughmemory for IPDS jobs (see theIBM Infoprint 21: User’s Guide).Go to step 3.
Reseat the IBM AFP/IPDSModule. If that does not fix theproblem, replace the IBMAFP/IPDS Module.
3. Power off and then power on the printer. Wait for theREADY message.
Does READY appear within 5 minutes?
Go to step 4. Return to “Solving the Problem”on page 46 with the new error
code or symptom.
4. Check printer function:a. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Can you print a Service Page?
Go to step 5 on page 61. Return to “Solving the Problem”on page 46 with the new error
code or symptom.
Chapter 1. Diagnosing Problems 60
Table 6. Coax/Twinax NIC Printing Problem (Printer) (continued)
Step Questions/Actions Yes No
5. Is the twinax or coax NIC indicated on the ServicePage?
Go to step 6. Go to step 9.
6. Check the NIC:a. Print a NIC Service Page from Tray 1 to the Main
Output Bin (see “Printing the Service Page” onpage 295).
Can you print a NIC Service Page?
Go to step 7. Go to step 9.
7. Check the job status:
When a job is sent, does the printer operator panelindicate the job’s arrival with any message?
The cabling and NIC are OK.Suspect a problem with menusettings, the IBM AFP/IPDSModule, the Controller Flash, orthe Controller PCB.
Go to step 8.
8. The NIC can communicate with the controller, but thesystem cannot communicate with the NIC.a. Check the cable connection at the back of the
twinax or coax NIC.
Is the connection light ON and the cableconnected?
Suspect a problem with thenetwork. Refer the systemadministrator to Twinax andCoax Configuration Guide,S544-5712, or call your nextlevel of support (see “TechnicalSupport” on page 618).
If the connection light is off, theproblem most likely is with thecustomer network. Ask thecustomer to verify their networksetup. If problems continue,replace the NIC.
9. There is a problem with the NIC or controller.a. Power off the printer.b. Reseat the NIC.c. Power on the printer.
Is the problem fixed?
Verify that the original customerjob prints correctly.
Go to step 10 on page 62.
Chapter 1. Diagnosing Problems 61
Table 6. Coax/Twinax NIC Printing Problem (Printer) (continued)
Step Questions/Actions Yes No
10. Replace the NIC:1. Power off the printer.2. Replace the NIC.3. Power on the printer.
Is the problem fixed?
Replacing the NIC solved theproblem. Verify that the originalcustomer job prints correctly.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Compact Flashv Controller PCB
Chapter 1. Diagnosing Problems 62
Ethernet / Token-Ring NIC Printing Problem (Printer)Symptom Explanation Suspected FRUs/Causes Probability
The printer is having problems printing with the Ethernet orToken-Ring NIC.
Ethernet NIC 40%
Token Ring NIC 40%
IBM AFP/IPDS Module 10%
Compact Flash 5%
Controller PCB 5%
Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer)
Step Questions/Actions Yes No
1. Is the problem only with IPDS jobs? Go to step 2. Go to step 3.
2. Check the IPDS Status:a. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295).
Is IPDS indicated on the Service Page?
Verify that there is enoughmemory for IPDS jobs (see theIBM Infoprint 21: User’s Guide).Go to step 3.
Reseat the IBM AFP/IPDSModule. If that does not fix theproblem, replace the IBMAFP/IPDS Module.
3. Power off and then power on the printer. Wait for theREADY message.
Does READY appear within 5 minutes?
Go to step 4. Return to “Solving the Problem”on page 46 with the new error
code or symptom.
4. Check printer function:a. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295).
Can you print a Service Page?
Go to step 5 on page 64. Return to “Solving the Problem”on page 46 with the new error
code or symptom.
Chapter 1. Diagnosing Problems 63
Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer) (continued)
Step Questions/Actions Yes No
5. Is the Ethernet or Token-Ring NIC indicated on theService Page?
Go to step 6. Go to step 9.
6. Check the NIC:a. Print a NIC Service Page from Tray 1 to the Main
Output Bin (see “Printing the Service Page” onpage 295).
Can you print a NIC Service Page?
Go to step 7. Go to step 9.
7. Check the job status:
When a job is sent, does the printer operator panelindicate the job’s arrival with any message?
The cabling and NIC are OK.Suspect a problem with menusettings, the IBM AFP/IPDSModule, the Controller Flash, orthe Controller PCB.
Go to step 8.
8. The NIC can communicate with the controller, but thesystem cannot communicate with the NIC.a. Check the cable connection at the back of the
Ethernet or Token-Ring NIC.
Is the connection light ON and the cableconnected?
There is probably a networkcabling problem or aconfiguration problem. Refer thesystem administrator to Ethernetand Token Ring ConfigurationGuide, S544-5711, or call yournext level of support (see“Technical Support” onpage 618).
If the connection light is off, theproblem most likely is with thecustomer network. Ask thecustomer to verify their networksetup. If problems continue,replace the NIC.
9. There is a problem with the NIC or controller.a. Power off the printer.b. Reseat the NIC.c. Power on the printer.
Is the problem fixed?
Verify that the original customerjob prints correctly.
Go to step 10 on page 65.
Chapter 1. Diagnosing Problems 64
Table 7. Ethernet / Token-Ring NIC Printing Problem (Printer) (continued)
Step Questions/Actions Yes No
10. Replace the NIC:1. Power off the printer.2. Replace the NIC.3. Power on the printer.
Is the problem fixed?
Replacing the NIC solved theproblem. Verify that the originalcustomer job prints correctly.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Compact Flashv Controller PCB
Chapter 1. Diagnosing Problems 65
Electrical Noise / Intermittent Operation (Printer)Symptom Explanation Suspected FRUs/Causes Probability
The printer is having intermittent problems, operation or errorcodes.
Toner Cartridge 40%
Main Power Switch 20%
HVPS 20%
LVPS 120V, LVPS 230V 10%
Fuser Asm 120 v, Fuser Asm 230 v 5%
MCU PCB 2%
Controller PCB 1%
5 V DC PCB 1%
Main Motor 1%
Table 8. Electrical Noise (Printer)
Step Questions/Actions Yes No
1. If there is any other electrical equipment, such as thefollowing, within 10 feet of the printer, isolate each, oneat a time.v Generatorsv Devices using motorsv Radio transmittersv X-ray machines
Do you still have an electrical noise problem?
Go to step 2 on page 67. Permanently relocate the printeror the interfering equipment.
Chapter 1. Diagnosing Problems 66
Table 8. Electrical Noise (Printer) (continued)
Step Questions/Actions Yes No
2. Isolate the Features.a. Remove all of the following options:v Duplex Asmv Offset Asmv Extra Traysv Env Tray Asm
Do you still have an electrical noise problem?
Go to step 3. Connect the options one at atime until the printer againbecomes inoperative. Replacethe last feature installed.
3. Perform a Safety Check.a. Perform “Power-Receptacle Safety-Check” on
page 34 and check all ground connections (see“Safety Ground” on page 33).
Do you still have an electrical noise problem?
Go to step 4 on page 68. If the problem is with the supplyoutlet, have the customercorrect the problem. If there is afaulty ground connection withinthe printer, repair or replace thatpart.
Chapter 1. Diagnosing Problems 67
Table 8. Electrical Noise (Printer) (continued)
Step Questions/Actions Yes No
4. Repair/replace the following, one at a time. After each replacement, determine if the problem is fixed.v Toner Cartridgev Main Power Switchv HVPSv LVPS 120V, LVPS 230Vv Fuser Asm 120 v, Fuser Asm 230 v
CAUTION:<2-43> High Temperature; switch off the printer and allow at least 30 minutes for parts in this area to coolbefore handling.
v MCU PCBv Controller PCBv 5 V DC PCBv Main Motor
If you have replaced all these parts and are still having the problem, go to “End of Diagnosing Problems and the ProblemRemains” on page 43.
Chapter 1. Diagnosing Problems 68
Excess NoiseSymptom Explanation Suspected FRUs/Causes Probability
The printer is creating excessive noise. Main Motor 40%
Gear Drive Asm 40%
Duplex Asm 10%
MCU PCB 5%
Harness (J34 - J341) 5%
Table 9. Excess Noise (Printer)
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray (see “Printing the Service Page” onpage 295.)
Is excess noise still audible?
Go to step 2 on page 70. The problem might be with thecustomer job. Verify the originaljob prints correctly.
Chapter 1. Diagnosing Problems 69
Table 9. Excess Noise (Printer) (continued)
Step Questions/Actions Yes No
2. Check the Paper Path:a. Power off the printer.b. Check the paper path throughout the entire printer
for blockage.c. Replace any damaged component.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is excess noise still audible?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Print a page with and without duplex:a. Enter the Service Mode (see “Accessing Service
Mode” on page 280).b. Print a Service Page from Tray 1 to the Main Output
Bin using the Duplex option (see ″Printing a ServicePage″ on page x.)
c. Print a Service Page from Tray 1 to the Main OutputBin without using the Duplex option.
d. If no duplex unit is installed on this machine, go tostep 3.
Is excess noise audible only when using duplex?
Go to step 7 on page 72. Go to step 4.
4. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Enter the Service Mode (see “Accessing Service
Mode” on page 280).d. Run Diagnostic 1100 (see “Diagnostic Menu” on
page 284).
Do all gears rotate correctly without excess noise?
Replace the MCU PCB. Go to step 5 on page 71.
Chapter 1. Diagnosing Problems 70
Table 9. Excess Noise (Printer) (continued)
Step Questions/Actions Yes No
5. Check the Main Motor:a. Power off the printer.b. Remove the Main Motor, leaving the Harness (J29 -
J291) attached to the MCU PCB.
DANGER
<1-10> Hazardous voltages are present. Donot touch the pins or the sockets of the powerreceptacle. Do not attempt to measurevoltages or make any other checks at thepower receptacle, the power cord, or thepower supply input before you perform thePower-Receptacle Safety-Check. Make thesechecks only if you are a qualified servicerepresentative or a qualified electrician.Inform the customer if the voltages or otherchecks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.
c. Enter the Service Mode (see “Accessing ServiceMode” on page 280).
d. Run Diagnostic 1100 (see “Diagnostic Menu” onpage 284).
Does the Main Motor rotate correctly without excessnoise?
Go to step 6 on page 72. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Motorv MCU PCB
Chapter 1. Diagnosing Problems 71
Table 9. Excess Noise (Printer) (continued)
Step Questions/Actions Yes No
6. Check the Gear Drive:a. Power off the printer.b. Check for damage by manually rotating the Main
Motor and watching the Gear Drive Asm.
Does the Gear Drive Asm function correctly withoutexcess noise?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCB
Repair/replace the Gear DriveAsm.
7. Check the Harness (J34 - J341):1. Power off the printer.2. Check the Harness (J34 - J341) from the MCU PCB
to make sure that it is properly connected and notdamaged.
Is the harness free of damage and properlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB
Repair/replace the Harness (J34- J341).
Chapter 1. Diagnosing Problems 72
Operator Panel, Controller and Power Problems (Printer)Symptom Explanation Suspected FRUs/Causes Probability
The Operator Panel LEDs, the display, or the push buttonsdo not function correctly. This might indicate a powerproblem.
Operator Panel 40%
LVPS 120V, LVPS 230V 25%
MCU PCB 18%
Controller PCB 10%
Compact Flash 1%
Memory DIMM 1%
5 V DC PCB 1%
Main Power Switch 1%
Harness (J4 - Operator Panel) 1%
Harness (J28 - J281) 1%
Harness (J1 - J101) 1%
Harness (AC - J285) 1%
Harness (J282 - J9, J288 - J9) 1%
Chapter 1. Diagnosing Problems 73
Table 10. Operator Panel, Controller and Power Problems (Printer)
Step Questions/Actions Yes No
1. Check Symptom:a. Power on the printer.b. Wait 6 minutes to be sure the symptom does not
change.
Does INFOPRINT 21 INITIALIZING display during the6 minutes?
Go to step 11 on page 76. Go to step 2.
2. Do any motors (including the fan motor) turn duringthe first five seconds after the printer is poweredon?
Go to step 3. Go to step 7 on page 75.
3. Check the Controller PCB:a. Power off the printer.b. Reseat the Controller PCB into the MCU PCB.c. Power on the printer.
Does INFOPRINT 21 INITIALIZING display?
A bad connection probablycaused the problem. If theproblem happens again, go tostep 7 on page 75.
Go to step 4.
4. Check the Harness (J4 - Operator Panel):a. Power off the printer.b. Check the Harness (J4 - Operator Panel) from the
Controller PCB to the Operator Panel to make surethat it is correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 5 on page 75. Repair/replace the Harness (J4 -Operator Panel).
Chapter 1. Diagnosing Problems 74
Table 10. Operator Panel, Controller and Power Problems (Printer) (continued)
Step Questions/Actions Yes No
5. Check the Harness (J282 - J9, J288 - J9):a. Power off the printer.b. Check the Harness (J282 - J9, J288 - J9) from the
LVPS and the 5 V DC PCB to the Controller PCB tomake sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 6. Repair/replace the Harness(J282 - J9, J288 - J9).
6. Check the Harness (J1 - J101):a. Power off the printer.b. Check the Harness (J1 - J101) from the LVPS to
the 5 V DC PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following:v Operator Panelv 5 V DC PCBv LVPS 120V, LVPS 230Vv Controller PCBv Memory DIMMv Compact Flash
Repair/replace Harness (J1 -J101).
7. Check the Power Receptacle:a. Power off the printer and remove the printer power
cord from the power outlet.b. Perform “Power-Receptacle Safety-Check” on
page 34 and check for the correct AC receptaclevoltage.
Is the power receptacle voltage correct?
Go to step 8 on page 76. A bad power outlet caused theproblem.
Chapter 1. Diagnosing Problems 75
Table 10. Operator Panel, Controller and Power Problems (Printer) (continued)
Step Questions/Actions Yes No
8. Check the Power Cord:a. Power off the printer.b. Disconnect the Power Cord from the printer.c. Check the continuity of the Power Cord.
Does the Power Cord have continuity?
Go to step 9. Replace the Power Cord.
9. Check the Harness (J28 - J281):a. Power off the printer.b. Check the Harness (J28 - J281) from the MCU PCB
to the LVPS to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 10. Repair/replace the Harness (J28- J281).
10. Check the Harness (AC - J285):a. Check the Harness (AC - J285) from the AC input
plug to the LVPS to make sure that it is correctlyconnected and not damaged.
b. Check for continuity from J285, pins 1 and 2, to thecorresponding AC input plug pins.
Is the harness free of damage, correctly connected,and have continuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Power Switchv LVPS 120V, LVPS 230V
Repair/replace the Harness (AC- J285).
11. Does the I/O INITIALIZING message display andthen always stay on?
Go to “Ethernet / Token-RingNIC Printing Problem (Printer)”on page 63.
Go to step 12.
12. Does the INFOPRINT 21 INITIALIZING or PLEASEWAIT INITIALIZING message display and thenalways stay on?
Go to step 14 on page 77. Go to step 13 on page 77.
Chapter 1. Diagnosing Problems 76
Table 10. Operator Panel, Controller and Power Problems (Printer) (continued)
Step Questions/Actions Yes No
13. Check the Harness (J282 - J9, J288 - J9):a. Power off the printer.b. Check the Harness (J282 - J9, J288 - J9) from the
LVPS and the 5 V DC PCB to the Controller PCB tomake sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Operator Panelv Controller PCBv 5 V DC PCBv LVPS 120V, LVPS 230V
Repair/replace the Harness(J282 - J9, J288 - J9).
14. Check the Features:1. Remove the installed features installed, one at a
time, in the order listed. After each removal, checkto see if the problem still exists.v Coax NICv Twinax NICv Ethernet NICv Token Ring NICv Hard Drivev IBM AFP/IPDS Modulev Font Flash
Did removing features fix the problem?
Repair/replace the feature lastremoved to fix the problem.
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Compact Flashv Controller PCB
Chapter 1. Diagnosing Problems 77
Offset Not Recognized (Printer)Go to “MAP 795: Offset Error” on page 225.
Chapter 1. Diagnosing Problems 78
Duplex Not Recognized (Printer)Go to “MAP 714: Duplex Error” on page 222.
Chapter 1. Diagnosing Problems 79
Envelope Not Recognized (Printer)Go to “MAP 772: ENV Error” on page 223.
Chapter 1. Diagnosing Problems 80
Tray 2 Not Recognized (Printer)Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic did not detect Tray 2. Option Paper Drawer 30%
Paper Size Sensor Asm 5%
MCU PCB 4%
Harness (J33 - J331) 1%
Table 11. Tray 2 Not Recognized (Printer)
Step Questions/Actions Yes No
1. Are there two Option Paper Drawers installed? Go to step 2. Go to step 3.
2. a. Switch the Option Paper Drawers so that Tray 2becomes Tray 3.
Do you still have a problem recognizing Tray 2?
Go to step 4 on page 82. Replace the Option PaperDrawer (Tray 3).
3. Replace the Option Paper Drawer (Tray 2):a. Power off the printer.b. Replace the Option Paper Drawer.c. Power on the printer.
Do you still have a problem recognizing Tray 2?
Install the original Option PaperDrawer. Go to step 4 onpage 82.
Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 81
Table 11. Tray 2 Not Recognized (Printer) (continued)
Step Questions/Actions Yes No
4. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 82
Tray 3 Not Recognized (Printer)Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic did not detect Tray 3. Option Paper Drawer 30%
Paper Size Sensor Asm 5%
MCU PCB 4%
Harness (J33 - J331) 1%
Table 12. Tray 3 Not Recognized (Printer)
Step Questions/Actions Yes No
1. Check the Option Paper Drawer (Tray 3):a. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.b. Power on the printer.
Do you still have a problem recognizing Tray 3?
Go to step 2. Replace the Option PaperDrawer (Tray 2).
2. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 83
MAP 002: Install New Toner CartridgeSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected low toner. Toner Cartridge 90%
Toner Sensor Asm 5%
MCU PCB 2%
Interface PCB 1%
Harness (J23 - J231) 1%
Harness (J42 - J421) 1%
Table 13. Map 002: Install New Toner Cartridge
Step Questions/Actions Yes No
1. Replace the Toner Cartridge:a. Power off the printer.b. Replace the Toner Cartridge.c. Power on the printer.
Do you still have error code 002?
Go to step 2. Problem solved.
2. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 3 on page 85. Repair/replace the Harness (J23- J231).
Chapter 1. Diagnosing Problems 84
Table 13. Map 002: Install New Toner Cartridge (continued)
Step Questions/Actions Yes No
3. Check the Harness (J42 - J421):1. Power off the printer.2. Check the Harness (J42 - J421) from the Toner
Sensor Asm to the Interface PCB to make sure thatit is correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Toner Sensor Asmv MCU PCBv Interface PCBv Harness (J42 - J421)
Repair/replace the Harness (J42- J421)
Chapter 1. Diagnosing Problems 85
MAP 006: Reseat Toner CartridgeSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic could not detect the Toner Cartridge. Toner Cartridge 80%
Toner Cartridge Key Sensor 17%
MCU PCB 2%
Harness (J25 - J251) 1%
Table 14. Map 006: Reseat Toner Cartridge
Step Questions/Actions Yes No
1. Replace the Toner Cartridge:Note: The Infoprint 21 checks for IBM Toner Cartridgesusing the Toner Cartridge Key Sensor. If a non-IBMToner Cartridge is installed, error code 006 isgenerated.a. Replace the IBM Toner Cartridge.
Do you still have error code 006?
Go to step 2. Problem solved.
2. Check the Harness (J25 - J251):1. Power off the printer.2. Check the Harness (J25 - J251) from the MCU PCB
to the Toner Cartridge Key Sensor to make surethat it is correctly connected and not damaged.To access Harness (J25 - J251), see “TonerCartridge Key Sensor” on page 490.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Toner Cartridge Key Sensorv MCU PCB
Repair/replace the Harness (J25- J251)
Chapter 1. Diagnosing Problems 86
MAP 008: Install New FuserSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Fuser Life has been reached. Fuser Asm 120 v, Fuser Asm 230 v 95%
MCU PCB 5%
Chapter 1. Diagnosing Problems 87
Table 15. Map 008: Install New Fuser
Step Questions/Actions Yes No
1. Replace the Fuser Asm 120 v, Fuser Asm 230 v:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.1. Power off the printer.2. Replace the Fuser Asm 120 v, Fuser Asm 230 v.3. Power on the printer.4. Reset the fuser count:
a. Press the Menu key until you see MACHINEINFO MENU.
b. Press the Item key until you see RESETFUSER CTR.
c. Press the Enter key.d. When you see the RESET COUNTER? /+YES, -NO
message, press the + key to reset the currentvalue to 0.
Do you still have error code 008?
Replace the MCU PCB. Problem solved.
Chapter 1. Diagnosing Problems 88
MAP 011: Tray x EmptySymptom Explanation Suspected FRUs/Causes Probability
One of the following:v The MCU PCB does not detect the empty tray.v The MCU PCB incorrectly detects an empty tray.
550-Sheet Tray Asm 40%
Option Paper Drawer 30%
Feed Asm 8%
Paper Size Sensor Asm 8%
Feed PCB 5%
MCU PCB 4%
No Paper Actuator 4%
Harness (J33 - J331) 1%
Table 16. Map 011: Tray x Empty
Step Questions/Actions Yes No
1. This map diagnoses two error conditions:a. The MCU PCB does not detect the empty tray (error
code 011 does not occur when a tray is empty).b. The MCU PCB incorrectly detects an empty tray
(error code 011 occurs when a tray has paper).
Is error code 011 occurring when the tray haspaper?
Go to step 2. Go to step 18 on page 93.
2. Does the error code 011 specify Tray 1? Go to step 13 on page 92. Go to step 3.
3. Does the error code 011 specify Tray 2? Go to step 4 on page 90. Go to step 10 on page 91.
Chapter 1. Diagnosing Problems 89
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
4. The error message specifies Tray 2.
Is there an Option Paper Drawer installed?
Go to step 5. Go to step 9 on page 91.
5. Are there two Option Paper Drawers installed? Go to step 6. Go to step 8.
6. Check the Option Paper Drawer (Tray 2):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.c. Power on the printer.
Does error code 011 specify Tray 2?
Go to step 9 on page 91. Go to step 7.
7. Check Tray 2:a. Power off the printer.b. Switch the trays so that Tray 2 becomes Tray 3.c. Power on the printer.
Does error code 011 specify Tray 3?
Replace the 550-Sheet TrayAsm (Tray 3).
Replace the Option PaperDrawer (Tray 2). If the problempersists, go to step 9 onpage 91.
8. Check Tray 2:a. Power off the printer.b. Switch the trays between Tray 1 and Tray 2.c. Power on the printer.
Does error code 011 specify Tray 2?
Go to step 9 on page 91. Replace the 550-Sheet TrayAsm in Tray 1.
Chapter 1. Diagnosing Problems 90
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
9. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Sizing PCB to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawerv Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
10. Are there two Option Paper Drawers installed? Go to step 11. Go to step 9.
11. Note: Based on answers to previous questions, Tray 3was specified in the error code 011.
Check the Option Paper Drawer (Tray 3):a. Power off the printer.b. Switch the Option Paper Drawers, including the
550-Sheet Tray Asms, so that Tray 3 becomes Tray2.
c. Power on the printer.
Does error code 011 specify Tray 3?
Go to step 9. Go to step 12.
12. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asms so that Tray 2
becomes Tray 3.c. Power on the printer.
Does error code 011 specify Tray 3?
Replace the 550-Sheet TrayAsm (currently in Tray 3).
Replace the Option PaperDrawer (currently Tray 2).
Chapter 1. Diagnosing Problems 91
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
13. Check the No Paper Actuator:a. Power off the printer.b. Check the No Paper Actuator and ensure that it is
undamaged and working correctly.
Is the No-Paper Actuator intact and workingcorrectly?
Go to step 14. Repair/replace the No PaperActuator.
14. Check the No-Paper Photo Sensor on the Tray 1 FeedPCB:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 1.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Lift the No-Paper Actuator to actuate the No-Paper
Photo Sensor in the Feed PCB.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Go to step 9 on page 91. Go to step 15.
15. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Sizing PCB to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 16 on page 93. Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 92
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
16. Is there an Option Paper Drawer installed? Go to step 17. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed PCBv 550-Sheet Tray Asm (Tray 1)v Paper Size Sensor Asmv MCU PCBv Feed Asm
17. Check the 550-Sheet Tray Asm (Tray 1):a. Power off the printer.b. Switch the 550-Sheet Tray Asms to that Tray 1
becomes Tray 2.c. Power on the printer.
Does error code 011 specify Tray 1?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed PCBv Paper Size Sensor Asmv MCU PCBv Feed Asm
Replace the 550-Sheet TrayAsm (in Tray 2).
18. Does the error occur with Tray 1? Go to step 27 on page 95. Go to step 19.
19. Does the error occur with Tray 2? Go to step 20. Go to step 24 on page 94.
20. The error occurs with Tray 2.
Is there an Option Paper Drawer installed?
Go to step 21 on page 94. Go to step 9 on page 91.
Chapter 1. Diagnosing Problems 93
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
21. Check the Option Paper Drawer (Tray 2):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 2.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the No-Paper Photo Sensor in Tray 2.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Go to step 9 on page 91. Go to step 22.
22. Are there two Option Paper Drawers installed? Go to step 23. Go to step 9 on page 91.
23. Check the Option Paper Drawer (Tray 2):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)d. Remove the 550-Sheet Tray Asm from Tray 2.e. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).f. Actuate the No-Paper Photo Sensor in Tray 2.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Replace the Option PaperDrawer (currently Tray 3). If theproblem persists, go to step 9on page 91.
Go to step 9 on page 91.
24. Are there two Option Paper Drawers installed? Go to step 25 on page 95. Go to step 9 on page 91.
Chapter 1. Diagnosing Problems 94
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
25. Check the Option Paper Drawer (Tray 3):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 3.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the No-Paper Photo Sensor in Tray 3.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Go to step 9 on page 91. Go to step 26.
26. Check the Option Paper Drawer (Tray 3):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)d. Remove the 550-Sheet Tray Asm from Tray 3.e. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).f. Actuate the No-Paper Photo Sensor in Tray 3.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Replace the Option PaperDrawer (currently Tray 2). If theproblem persists, go to step 9on page 91.
Go to step 9 on page 91.
27. Check the No-Paper Actuator:a. Power off the printer.b. Check the No Paper Actuator and ensure that it is
undamaged and working correctly.
Is the No-Paper Actuator intact and workingcorrectly?
Go to step 28 on page 96. Repair/replace the No PaperActuator.
Chapter 1. Diagnosing Problems 95
Table 16. Map 011: Tray x Empty (continued)
Step Questions/Actions Yes No
28. Check the No-Paper Sensor on the Tray 1 Feed PCB:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 1.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Lift the No-Paper Actuator to actuate the No-Paper
Photo Sensor on the Feed PCB.
Did the Diagnostic display “Sensor/Switch OK”when the No-Paper Actuator was lifted?
Go to step 9 on page 91. Go to step 29.
29. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Sizing PCB to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v 550-Sheet Tray Asm (Tray 1)v Feed PCBv Paper Size Sensor Asmv MCU PCBv Feed Asm
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 96
MAP 012: (Aux/Env) EmptySymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Aux or Envelope Tray has no paper. Aux Tray Asm 45%
Env Tray Asm 45%
MCU PCB 5%
Interface PCB 2%
Harness (J23 - J231) 1%
Harness (J45 - J451) 1%
Env Connector - Female 1%
Table 17. Map 012: (Aux/Env) Empty
Step Questions/Actions Yes No
1. There are two reasons to be at this map.a. The MCU PCB does not detect the empty tray.b. The MCU PCB incorrectly detects an empty tray.
Is the MCU PCB always detecting a Tray Emptycondition?
Yes, the Tray Empty erroralways appears. Go to step 2.
No, the Tray Empty error neverappears. This will cause a 221Paper Jam when there is nopaper in the tray. Go to step 2.
2. Is the Tray Empty problem with the Aux Tray? Yes, the error is with the AuxTray. Go to step 3 on page 98.
No, the error is with theEnvelope Tray. Go to step 7 onpage 99.
Chapter 1. Diagnosing Problems 97
Table 17. Map 012: (Aux/Env) Empty (continued)
Step Questions/Actions Yes No
3. Check the Aux Tray No-Paper Sensor Actuator:a. Power off the printer.b. Check the Aux Tray No-Paper Sensor Actuator and
ensure that it is not damaged and working correctly.c. Clean the Aux Tray No-Paper Sensor.
Is the Aux Tray No-Paper Sensor Actuator intactand working correctly?
Go to step 4. Repair/replace the Aux TrayNo-Paper Sensor Actuator.
4. Check the Aux Tray No-Paper Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the paper from the Aux Tray.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Aux Tray No-Paper Photo Sensor.
Did the Diagnostic display “Sensor/Switch OK”when the Aux Tray No-Paper Sensor was actuated?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCB
Go to step 5.
5. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 6 on page 99. Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 98
Table 17. Map 012: (Aux/Env) Empty (continued)
Step Questions/Actions Yes No
6. Check the Harness (J45 - J4511):a. Power off the printer.b. Check the Harness (J45 - J451) from the Interface
PCB to the Aux Tray No-Paper Photo Sensor tomake sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCB
Repair/replace the Harness (J45- J451).
7. Is there an Envelope Tray attached to this printer? Go to step 8. Replace the MCU PCB.
8. Check the Env No-Paper Actuator:a. Check the Env No-Paper Actuator and ensure that it
is not damaged and working correctly.b. Clean the Env No-Paper Sensor.
Is the Env No-Paper Actuator intact and workingcorrectly?
Go to step 9. Repair/replace the EnvNo-Paper Actuator.
9. Check the Env No-Paper Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the paper from the Env Tray.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Env No-Paper Photo Sensor.
Did the Diagnostic display “Sensor/Switch OK”when the Env No-Paper Sensor was actuated?
Replace the MCU PCB. Go to step 10 on page 100.
Chapter 1. Diagnosing Problems 99
Table 17. Map 012: (Aux/Env) Empty (continued)
Step Questions/Actions Yes No
10. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 11. Repair/replace the Harness (J33- J331).
11. Check the Env Connector -Female:1. Power off the printer.2. Check the Env Connector -Female to make sure
that it is correctly connected and not damaged fromthe Interface PCB.
Is the connector in good condition?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCB
Repair/replace the EnvConnector - Female.
Chapter 1. Diagnosing Problems 100
MAP 015: Tray x LowSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a tray is low on paper. Printing is stillpossible.
550-Sheet Tray Asm 45%
Paper Low Photo Sensor 20%
Option Paper Drawer 15%
Feed Asm 10%
Paper Size Sensor Asm 5%
MCU PCB 3%
Harness (J33 - J331) 1%
Harness (J66 - J661, J662) 1%
Table 18. Map 015: Tray x Low
Step Questions/Actions Yes No
1. Verify the error:a. Power off the printer.b. Reload the specified tray with the correct size
paper.c. Make sure the paper size guides are against the
paper.d. Close the tray.e. Power on the printer.
Do you still have error code 015?
Go to step 2. Problem solved.
2. Does error code 015 specify tray 1? Go to step 18 on page 106. Go to step 3 on page 102.
Chapter 1. Diagnosing Problems 101
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
3. Does error code 015 specify tray 2? Go to step 4. Go to step 12 on page 104.
4. Is there an Option Paper Drawer installed? Go to step 5. Replace the MCU PCB.
5. Are there two Option Paper Drawers installed? Go to step 6. Go to step 8.
6. Check the Option Paper Drawer (Tray 2):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.c. Power on the printer.
Does error code 015 specify Tray 2?
Switch the Tray 2 and Tray 3drawers back.
Go to step 11 on page 104.
Go to step 7.
7. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Switch the 550-Sheet Tray Asms between Tray 3
and Tray 2.c. Power on the printer.
Does error code 015 specify Tray 2?
Replace the 550-Sheet TrayAsm (in Tray 2).
Replace the Option PaperDrawer (currently Tray 3).
8. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asms between Tray 2
and Tray 1.c. Power on the printer.
Does error code 015 specify Tray 2?
Go to step 9 on page 103. Replace the 550-Sheet TrayAsm (in Tray 1).
Chapter 1. Diagnosing Problems 102
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
9. Check the Option Paper Drawer Paper Low PhotoSensor Actuator (Tray 2):a. Power off the printer.b. Check the Option Paper Drawer Low Paper Sensor
Actuator and ensure that it is not damaged andworking correctly.
c. Clean the Option Paper Drawer Low Paper Sensor.
Is the Option Paper Drawer Low Paper SensorActuator intact and working correctly?
Go to step 10. Repair/replace the Option PaperDrawer Low Paper SensorActuator.
10. Check the Option Paper Drawer Paper Low PhotoSensor (Tray 2):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from the Option
Paper Drawer (Tray 2).c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Paper Low Photo Sensor in the Option
Paper Drawer (Tray 2).
Did the Diagnostic display “Sensor/Switch OK”when the Low Paper Sensor was actuated?
Replace the MCU PCB. Go to step 11 on page 104.
Chapter 1. Diagnosing Problems 103
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
11. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
12. Is there two Option Paper Drawers installed? Go to step 13. Replace the MCU PCB.
13. Check the Option Paper Drawer (Tray 3):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.c. Power on the printer.
Does error code 015 specify Tray 3?
Go to step 15 on page 105. Go to step 14.
14. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asms between Tray 2
and Tray 3.c. Power on the printer.
Does error code 015 specify Tray 3?
Replace the 550-Sheet TrayAsm (in Tray 3).
Replace the Option PaperDrawer (currently Tray 2).
Chapter 1. Diagnosing Problems 104
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
15. Check the Option Paper Drawer Paper Low PhotoSensor Actuator (Tray 3):a. Power off the printer.b. Check the Option Paper Drawer Low Paper Sensor
Actuator and ensure that it is not damaged andworking correctly.
c. Clean the Option Paper Drawer Low Paper Sensor.
Is the Option Paper Drawer Low Paper SensorActuator intact and working correctly?
Go to step 16. Repair/replace the Option PaperDrawer Low Paper SensorActuator.
16. Check the Option Paper Drawer Paper Low PhotoSensor (Tray 3):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from the Option
Paper Drawer (Tray 3).c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Paper Low Photo Sensor in the Option
Paper Drawer (Tray 3).
Did the Diagnostic display “Sensor/Switch OK”when the Low Paper Sensor was actuated?
Replace the MCU PCB. Go to step 17 on page 106.
Chapter 1. Diagnosing Problems 105
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
17. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
18. Check the Feed Asm Paper Low Photo SensorActuator:a. Power off the printer.b. Check the Feed Asm Low Paper Sensor Actuator
and ensure that it is not damaged and workingcorrectly.
c. Clean the Feed Asm Low Paper Sensor.
Is the Feed Asm Low Paper Sensor Actuator intactand working correctly?
Go to step 19. Repair/replace the Feed AsmLow Paper Sensor Actuator.
19. Check the Feed Asm Paper Low Photo Sensor (Tray 1):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the 550-Sheet Tray Asm from Tray 1.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Paper Low Photo Sensor in the Feed
Asm (Tray 1) by lifting the Feed Asm Low PaperSensor Actuator.
Did the Diagnostic display “Sensor/Switch OK”when the Low Paper Sensor was actuated?
Replace the MCU PCB. Go to step 20 on page 107.
Chapter 1. Diagnosing Problems 106
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
20. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 21. Repair/replace the Harness (J33- J331).
21. Is there an Option Paper Drawer installed? Go to step 23. Go to step 22.
22. Check the Harness (J66 - J661, J662):a. Power off the printer.b. Check the Harness (J66 - J661, J662) from the Low
Paper Photo Sensor to the Feed PCB to make surethat it is correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Low Photo Sensorv 550-Sheet Tray Asm (Tray 1)v Paper Size Sensor Asmv MCU PCBv Feed Asm
Repair/replace the Harness (J66- J661, J662).
23. Check the 550-Sheet Tray Asm (Tray 1):a. Power off the printer.b. Switch the 550-Sheet Tray Asms between Tray 1
and Tray 2.c. Power on the printer.
Does error code 015 specify Tray 1?
Go to step 24 on page 108. Replace the 550-Sheet TrayAsm (in Tray 2).
Chapter 1. Diagnosing Problems 107
Table 18. Map 015: Tray x Low (continued)
Step Questions/Actions Yes No
24. Check the Harness (J66 - J661, J662):1. Power off the printer.2. Check the Harness (J66 - J661, J662) from the Low
Paper Photo Sensor to the Feed PCB to make surethat it is correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Low Photo Sensorv Paper Size Sensor Asmv MCU PCBv Feed Asm
Repair/replace the Harness (J66- J661, J662).
Chapter 1. Diagnosing Problems 108
MAP 016: Adjust Guides For Paper Size Or Set Size In MenuSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the menu is set for autosense, but thepaper guides are not in an autosense position.
550-Sheet Tray Asm 80%
Paper Size Sensor Asm 17%
MCU PCB 2%
Harness (J33 - J331) 1%
Table 19. Map 016: Adjust Guides For Paper Size Or Set Size In Menu
Step Questions/Actions Yes No
1. This error is usually caused by the 550-Sheet Tray Asminserted skewed.
Is the 550-Sheet Tray Asm inserted correctly?
Go to step 2. Reinsert the tray or replace the550-Sheet Tray Asm
2. This error can also be caused by incorrect settings inthe printer menu.
Is the TRAnSIZ item in the Paper Menu set toAUTO?
Go to step 3 on page 110. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv MCU PCB
Chapter 1. Diagnosing Problems 109
Table 19. Map 016: Adjust Guides For Paper Size Or Set Size In Menu (continued)
Step Questions/Actions Yes No
3. Check the 550-Sheet Tray Asm Guides:a. Remove the tray with the error.b. Verify correct operation of the paper guides.c. Set the paper guides to an autosensed position.
Note: Select AUTO for the following paper sizes:LETTER, LEGAL, FOLIO, A4, B5-JIS, A5, or EXEC.For other paper sizes, select that size in the PaperMenu.
Is the 550-Sheet Tray Asm working correctly?
Go to step 4. Repair/replace 550-Sheet TrayAsm.
4. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCBv Controller PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 110
MAP 017: Adjust Guides For Paper Size Or Set Size In MenuSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected an error with the paper sizeauto-sensing circuit.
550-Sheet Tray Asm 80%
Paper Size Sensor Asm 17%
MCU PCB 2%
Harness (J33 - J331) 1%
Table 20. Map 017: Adjust Guides For Paper Size Or Set Size In Menu
Step Questions/Actions Yes No
1. Theoretically, this error should never occur. Continuewith the following map steps, but also consider callingyour next level of support.
Is the TRAnSIZ item in the Paper Menu set toAUTO?
Go to step 2. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv MCU PCB
2. Check the 550-Sheet Tray Asm Guides:a. Remove the tray with the error.b. Verify correct operation of the paper guides.c. Set the paper guides to an autosensed position.
Note: Select AUTO for the following paper sizes:LETTER, LEGAL, FOLIO, A4, B5-JIS, A5, or EXEC.For other paper sizes, select that size in the PaperMenu.
Is the 550-Sheet Tray Asm working correctly?
Go to step 3 on page 112. Repair/replace 550-Sheet TrayAsm.
Chapter 1. Diagnosing Problems 111
Table 20. Map 017: Adjust Guides For Paper Size Or Set Size In Menu (continued)
Step Questions/Actions Yes No
3. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCBv Controller PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 112
MAP 031: Unload Paper From Main Output BinSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Main Output Bin is full of paper. Full Stack Photo Sensor 60%
MCU PCB 35%
Harness (J31 - J311) 5%
MCU Logic did not detect that the Main Output Bin is full ofpaper.
Full Stack Photo Sensor 60%
MCU PCB 35%
Harness (J31 - J311) 5%
Table 21. Map 031: Unload Paper From Main Output Bin
Step Questions/Actions Yes No
1. There are two reasons to be at this map.a. The MCU PCB did not detect Full Stack.b. The MCU PCB always detects Full Stack.
Note: If the Offset Output Bin is not installed, theprinter can print 107 pages to the main output bin afterthe Full Stack Photo Sensor stops toggling. If the OffsetOutput Bin is installed, the printer can print 7 pagesafter the Full Stack Photo Sensor stops toggling.
Is the MCU PCB always detecting a Full Stackcondition?
Yes, the Full Stack error alwaysappears. Go to step 2 onpage 114.
No, the Full Stack error neverappears. This will cause a 272Paper Jam. Go to step 2 onpage 114.
Chapter 1. Diagnosing Problems 113
Table 21. Map 031: Unload Paper From Main Output Bin (continued)
Step Questions/Actions Yes No
2. Check the Full Stack Photo Sensor Actuator:a. Power off the printer.b. Check the Full Stack Sensor Actuator and ensure
that it is not damaged and working correctly.c. Clean the Full Stack Sensor.
Is the Full Stack Sensor Actuator intact and workingcorrectly?
Go to step 3. Repair/replace the Full StackActuator.
3. Check the Full Stack Photo Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the paper from the Main Output Bin.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Full Stack Photo Sensor by lifting the
Full Stack Actuator.
Did the Diagnostic display “Sensor/Switch OK”when the Full Stack Photo Sensor was actuated?
Replace the MCU PCB. Go to step 4.
4. Check the Harness (J31 - J311):1. Power off the printer.2. Check the Harness (J31 - J311) from the MCU PCB
to the Full Stack Photo Sensor to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Full Stack Photo Sensorv MCU PCB
Repair/replace the Harness (J31- J311).
Chapter 1. Diagnosing Problems 114
MAP 035: Unload Paper From Offset BinSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Offset Bin is full of paper. Offset Asm 60%
MCU PCB 35%
Harness (J35 - J351) 5%
MCU Logic did not detect that the Offset Bin is full of paper. Offset Asm 60%
MCU PCB 35%
Harness (J35 - J351) 5%
Table 22. Map 035: Unload Paper From Offset Bin
Step Questions/Actions Yes No
1. There are two reasons to be at this map.a. The MCU PCB did not detect Full Stack.b. The MCU PCB always detects Full Stack.
Is the MCU PCB always detecting a Full Stackcondition?
Yes, the Full Stack error alwaysappears. Go to step 2.
No, the Full Stack error neverappears. This will cause a 272Paper Jam. Go to step 2.
2. Check the Harness (J35 - J351):1. Power off the printer.2. Check the Harness (J35 - J351) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB
Repair/replace the Harness (J35- J351).
Chapter 1. Diagnosing Problems 115
MAP 041: Install Tray 1Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that Tray 1 is missing. 550-Sheet Tray Asm 60%
Paper Size Sensor Asm 30%
MCU PCB 5%
Feed Asm 3%
Harness (J33 - J331) 1%
Harness (J66 - J661, J662) 1%
Table 23. Map 041: Install Tray 1
Step Questions/Actions Yes No
1. Check the 550-Sheet Tray Asm:a. Power off the printer.b. Remove the 550-Sheet Tray Asm.c. Check the paper-lift mechanism for damage or wear.
Make sure to check the copper tray connectorcontacts located on the left side of the tray asm,and their matching contacts inside the tray opening.
d. Install the 550-Sheet Tray Asm.e. Power on the printer.
Do you still have error code 041?
Go to step 2. Problem solved.
2. Is there an Option Paper Drawer installed on thisprinter?
Go to step 3 on page 117. Go to step 4 on page 117.
Chapter 1. Diagnosing Problems 116
Table 23. Map 041: Install Tray 1 (continued)
Step Questions/Actions Yes No
3. Check the 550-Sheet Tray Asm (Tray 1):a. Switch the 550-Sheet Tray Asm between Tray 1 and
Tray 2.
Do you still have a “041 Tray Missing - Tray 1”error?
Go to step 4. Replace the 550-Sheet TrayAsm Asm (Tray 2).
4. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 5. Repair/replace the Harness (J33- J331).
5. Check the Harness (J66 - J661, J662):1. Power off the printer.2. Check the Harness (J66 - J661, J662) from the Lift
Control Photo Sensor to the Feed PCB to makesure that it is correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Lift Control Photo Sensorv Feed PCBv Paper Size Sensor Asmv MCU PCBv 550-Sheet Tray Asm
Repair/replace the Harness (J66- J661, J662).
Chapter 1. Diagnosing Problems 117
MAP 042: Install Tray 2Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that Tray 2 is missing. 550-Sheet Tray Asm 60%
Option Paper Drawer 30%
Paper Size Sensor Asm 5%
MCU PCB 4%
Harness (J33 - J331) 1%
Table 24. Map 042: Install Tray 2
Step Questions/Actions Yes No
1. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Remove the Tray 2 550-Sheet Tray Asm.c. Check the tray for damage and wear.d. Install the 550-Sheet Tray Asm.e. Power on the printer.
Do you still have error code 042?
Go to step 2. Problem solved.
2. Check the 550-Sheet Tray Asm (Tray 2):a. Power off the printer.b. Switch the 550-Sheet Tray Asm between Tray 2 and
Tray 1.c. Power on the printer.
Do you still have a “042 Tray Missing - Tray 2”error?
Go to step 3 on page 119. Replace the 550-Sheet TrayAsm Asm (Tray 1).
Chapter 1. Diagnosing Problems 118
Table 24. Map 042: Install Tray 2 (continued)
Step Questions/Actions Yes No
3. Are there two Option Paper Drawers installed? Go to step 4. Go to step 6.
4. Check the Option Paper Drawer (Tray 2):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.c. Power on the printer.
Do you still have a “042 Tray Missing - Tray 2”error?
Go to step 5. Replace the Option PaperDrawer (Tray 3).
5. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
6. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 119
MAP 043: Install Tray 3Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that Tray 3 is missing. 550-Sheet Tray Asm 60%
Option Paper Drawer 30%
Paper Size Sensor Asm 5%
MCU PCB 4%
Harness (J33 - J331) 1%
Table 25. Map 043: Install Tray 3
Step Questions/Actions Yes No
1. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Remove the 550-Sheet Tray Asm.c. Check for damage or wear.d. Install the 550-Sheet Tray Asm.e. Power on the printer.
Do you still have error code 043?
Go to step 2 on page 121. Problem solved.
Chapter 1. Diagnosing Problems 120
Table 25. Map 043: Install Tray 3 (continued)
Step Questions/Actions Yes No
2. Check the 550-Sheet Tray Asm (Tray 3):a. Power off the printer.b. Switch the Tray 2 and Tray 3 550-Sheet Tray Asm
so that the Tray 2 550-Sheet Tray Asm becomes theTray 3 550-Sheet Tray Asm.
c. Power on the printer.
Do you still have a “043 Tray Missing - Tray 3”error?
Go to step 3. Replace the 550-Sheet TrayAsm Asm currently in Tray 2.
3. Check the Option Paper Drawer (Tray 3):a. Power off the printer.b. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.c. Power on the printer.
Do you still have a “043 Tray Missing - Tray 3”error?
Go to step 4. Replace the Option PaperDrawer (Tray 2).
4. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 121
MAP 049: Close Face-up Output Bin When DuplexingSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Face-up Output Bin is open whentrying to print duplex.
Duplex Face-up Photo Sensor 80%
MCU PCB 15%
Harness (J34 - J341) (see “Harness (J34-P341)” onpage 403)
4%
Rear Cover Asm (With Face-Up Bin), Rear CoverAsm (Without Face-Up Bin)
1%
Table 26. Map 049: Close Face-up Output Bin When Duplexing
Step Questions/Actions Yes No
1. Is there a duplex unit installed on this printer? Go to step 2. Replace the MCU PCB.
2. Is the customer trying to print a duplex job with theFace-up Output Bin open?
The printer cannot print duplexwith the Face-up Output Binopen. Close the Face-up OutputBin to print duplex.
Go to step 3.
3. Is the customer trying to print with the Face-upOutput Bin open?
The print job might be duplex,which would generate this error.Check the customer’s driversand printer settings.
Go to step 4 on page 123.
Chapter 1. Diagnosing Problems 122
Table 26. Map 049: Close Face-up Output Bin When Duplexing (continued)
Step Questions/Actions Yes No
4. Check the Duplex Face Up Photo Sensor Actuator:a. Power off the printer.b. Check the Duplex Face Up Photo Sensor Actuator
and ensure that it is not damaged and workingcorrectly.
c. Clean the Duplex Face Up Photo Sensor.
Is the Duplex Face Up Photo Sensor Actuator intactand working correctly?
Go to step 5. Repair/replace the DuplexFace-up Photo Sensor Actuator.
5. Check the Duplex Face Up Photo Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Open the Rear Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Actuate the Face Up Photo Sensor by blocking the
sensor with a piece of paper.
Does the Diagnostic display “Sensor/Switch OK”when the Face Up Photo Sensor is blocked?
Go to step 6. Go to step 7 on page 124.
6. Check the Rear Cover:a. Check the Rear Cover to ensure that the Face Up
Tab on the Rear Cover that activates the Face UpPhoto Sensor is intact and working correctly.
Is the Rear Cover in good condition?
Replace the MCU PCB. Replace the Rear Cover.
Chapter 1. Diagnosing Problems 123
Table 26. Map 049: Close Face-up Output Bin When Duplexing (continued)
Step Questions/Actions Yes No
7. Check the Harness (J34 - J341):1. Power off the printer.2. Check the Harness (J34 - J341) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB
Repair/replace the Harness (J34- J341).
Chapter 1. Diagnosing Problems 124
MAP 074: Close Front CoverSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Front Cover is open. Front Cover Interlock Switch 80%
MCU PCB 10%
LVPS 120V, LVPS 230V 3%
Harness (J28 - J281) 1%
Front Cover Asm 1%
Table 27. Map 074: Close Front Cover
Step Questions/Actions Yes No
1. Check the Front Cover Interlock Switch:a. Power on the printer.b. Open the Front Cover.c. Manually activate the Front Cover Interlock Switch.d. Ensure that the metal actuator on the switch is
intact, not deformed and working correctly.
Does error code 074 occur with the Front CoverInterlock Switch activated?
Go to step 2 on page 126. The Front Cover Asm is notactivating the Front CoverInterlock Switch. Replace theFront Cover Asm if the stand-offon the Front Cover Asm thatactuates the Front CoverInterlock Switch is broken.
Chapter 1. Diagnosing Problems 125
Table 27. Map 074: Close Front Cover (continued)
Step Questions/Actions Yes No
2. Check the Front Cover Interlock Switch:a. Power off the printer.b. Disconnect P/J 284 from the LVPS.c. Check the continuity of the Front Cover Interlock
Switch on harness J284 from pin 1 to pin 2:v The switch should have continuity when
activated.v The switch should not have continuity when not
activated.
Does the Front Cover Interlock Switch havecontinuity?
Reconnect P/J284. Go to step 3on page 127.
Replace the Front CoverInterlock Switch.
Chapter 1. Diagnosing Problems 126
Table 27. Map 074: Close Front Cover (continued)
Step Questions/Actions Yes No
3. Check the 24 V DC on the LVPS:
DANGER
<1-10> Hazardous voltages are present. Do nottouch the pins or the sockets of the powerreceptacle. Do not attempt to measure voltagesor make any other checks at the powerreceptacle, the power cord, or the power supplyinput before you perform the Power-ReceptacleSafety-Check. Make these checks only if you area qualified service representative or a qualifiedelectrician. Inform the customer if the voltages orother checks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.
a. Reconnect P/J284 on the LVPS.b. Power on the printer.c. Measure the following voltage:
PJ284-2 to frame ground: 24 V DC
Is there 24 V DC between PJ284-2 and frameground?
Go to step 4 on page 128. Replace the LVPS 120V, LVPS230V.
Chapter 1. Diagnosing Problems 127
Table 27. Map 074: Close Front Cover (continued)
Step Questions/Actions Yes No
4. Check the Harness (J28 - J281):1. Power off the printer.2. Check the Harness (J28 - J281) from the MCU PCB
to the LVPS to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following:v MCU PCBv LVPS 120V, LVPS 230V
Repair/replace the Harness (J28- J281).
Chapter 1. Diagnosing Problems 128
MAP 075: Close Rear CoverSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Rear Cover is open. Rear Cover Interlock Switch 90%
MCU PCB 7%
Rear Cover Asm (With Face-Up Bin) Rear Cover Asm(Without Face-Up Bin)
3%
Table 28. Map 075: Close Rear Cover
Step Questions/Actions Yes No
1. Check the Rear Cover Interlock Switch:a. Power on the printer.b. Open the Rear Cover.c. Manually activate the Rear Cover Interlock Switch.d. Ensure that the metal actuator on the switch is
intact, not deformed and working correctly.
Does error code 075 occur when the Rear CoverInterlock Switch activated?
Go to step 2 on page 130. The Rear Cover is not activatingthe Rear Cover Interlock Switch.Replace the Rear Cover Asm(With Face-Up Bin), Rear CoverAsm (Without Face-Up Bin) ifthe stand-off on the Rear Coverthat actuates the Rear CoverInterlock Switch is broken.
Chapter 1. Diagnosing Problems 129
Table 28. Map 075: Close Rear Cover (continued)
Step Questions/Actions Yes No
2. Check the Rear Cover Interlock Switch:1. Power off the printer.2. Disconnect P/J30 from the MCU PCB.3. Check the continuity of the Rear Cover Interlock
Switch on Harness J30 from pin 1 to pin 2:v The switch should have continuity when
activated.v The switch should not have continuity when not
activated (the cover is open).
Is the Rear Cover Interlock Switch operatingcorrectly?
Replace the MCU PCB. Replace the Rear CoverInterlock Switch.
Chapter 1. Diagnosing Problems 130
MAP 200: Wrong Paper Size - DuplexSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that the paper traveling through theduplex unit is the wrong size
MCU PCB 50%
Duplex Asm 50%
Table 29. Map 200: Wrong Paper Size - Duplex
Step Questions/Actions Yes No
1. Does the printer have a duplex unit installed? Go to step 2. Replace the MCU PCB.
2. Check the paper:1. Power off the printer.2. Remove all paper from the printer.3. Verify all paper is within the specification for duplex
printing. See the Infoprint 21 User’s Guide for paperspecifications.
Is the paper within the specification for duplexprinting?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB
Replace the paper with a correctsize of paper or stop printingduplex.
Chapter 1. Diagnosing Problems 131
MAP 201: Wrong Paper Size - TraySymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the tray does not contain the paper sizespecified in the Paper Menu.
550-Sheet Tray Asm 80%
Paper Size Sensor Asm 17%
MCU PCB 2%
Harness (J33 - J331) 1%
Table 30. Map 201: Wrong Paper Size - Tray
Step Questions/Actions Yes No
1. This error is usually caused by incorrect settings in theprinter menu.
Is the paper size in the printer menu set for″autosense ″?
Go to step 2. Set the menu for the correctpaper size, or use autosense. Ifthe problem persists, go to step2.
2. Check the 550-Sheet Tray Asm Guides:a. Remove the tray with the error.b. Verify correct operation of the paper guides.c. Set the paper guides to an autosensed position.
Note: Select AUTO for the following paper sizes:LETTER, LEGAL, FOLIO, A4, B5-JIS, A5, or EXEC.For other paper sizes, select that size in the PaperMenu.
Is the 550-Sheet Tray Asm working correctly?
Go to step 3 on page 133. Repair/replace 550-Sheet TrayAsm.
Chapter 1. Diagnosing Problems 132
Table 30. Map 201: Wrong Paper Size - Tray (continued)
Step Questions/Actions Yes No
3. Check the Harness (J33 - J331):1. Power off the printer.2. Check the Harness (J33 - J331) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Paper Size Sensor Asmv MCU PCBv Controller PCB
Repair/replace the Harness (J33- J331).
Chapter 1. Diagnosing Problems 133
MAP 220: Paper Jam - Early FeedSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Registration Sensor was activatedtoo soon after the Feed Clutch was activated.
Registration Sensor 15%
Feed Roll Clutch 10%
Registration Actuator 8%
550-Sheet Tray Asm 8%
Option Paper Drawer 8%
Paper Handling Asm 8%
Feed Asm 7%
Paper Size Sensor Asm 5%
Main Motor 5%
Gear Drive Asm 5%
Pick Clutch - Electric 5%
Feed PCB 3%
MCU PCB 3%
Paper Size PCB 3%
Interface PCB 3%
Harness (J43 - J432, J433) 1%
Harness (J33 - J331) 1%
Harness (J51 - J511) 1%
Harness (J23 - J231) 1%
Chapter 1. Diagnosing Problems 134
Table 31. Map 220: Paper Jam - Early Feed
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Run Service Pages from all trays, including the Aux
tray. See “Printing the Service Page” on page 295.
Does error code 220 occur from all trays?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Does error code 220 occur with all inputs? Go to step 3. Go to step 11 on page 139.
3. Check the paper path:a. Power off the printer.b. Check the paper path from all trays to the
Registration Sensor for blockage. Especially checkbetween the Center Registration Chute and LowerRegistration Chute in the Paper handling Asm.
c. Replace any damaged component.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 4. Problem solved. Verify theoriginal customer job printscorrectly.
4. Check the Registration Sensor Actuator:a. Power off the printer.b. Check the Registration Sensor Actuator and ensure
that it is not damaged and working correctly.c. Clean the Registration Sensor.
Is the Registration Sensor Actuator intact andworking correctly?
Go to step 5 on page 136. Repair/replace the RegistrationSensor Actuator.
Chapter 1. Diagnosing Problems 135
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
5. Check the Registration Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Open the Front Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Move the Registration Actuator to activate the
Registration Sensor.
Did the Diagnostic display “Sensor/Switch OK”when the Registration Sensor was actuated?
Go to step 8 on page 137. Go to step 6.
6. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 7. Repair/replace the Harness (J23- J231).
7. Check the Harness (J43 - J432, J433):a. Power off the printer.b. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Sensor to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCB
Repair/replace the Harness (J43- J432, J433).
Chapter 1. Diagnosing Problems 136
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
8. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Close the Front Cover.d. Enter Service Mode (see “Accessing Service Mode”
on page 280.)e. Run Diagnostic 1100 (see “Diagnostic Menu” on
page 284).
Do all gears rotate correctly?
Go to step 42 on page 146. Go to step 9 on page 138.
Chapter 1. Diagnosing Problems 137
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
9. Check the Main Motor:a. Power off the printer.b. Remove the Main Motor, leaving the Harness (J29 -
J291) attached to the MCU PCB.
DANGER
<1-10> Hazardous voltages are present. Donot touch the pins or the sockets of the powerreceptacle. Do not attempt to measurevoltages or make any other checks at thepower receptacle, the power cord, or thepower supply input before you perform thePower-Receptacle Safety-Check. Make thesechecks only if you are a qualified servicerepresentative or a qualified electrician.Inform the customer if the voltages or otherchecks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.
c. Enter Service Mode (see “Accessing Service Mode”on page 280.)
d. Run Diagnostic 1100 (see “Diagnostic Menu” onpage 284).
Does the Main Motor rotate correctly?
Go to step 10 on page 139. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Motorv MCU PCB
Chapter 1. Diagnosing Problems 138
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
10. Check the Gear Drive:a. Power off the printer.b. Check for damage by manually rotating the Main
Motor and watching the Gear Drive Asm.
Does the Gear Drive Asm function correctly?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Handling Asm
Repair/replace the Gear DriveAsm.
11. Does error code 220 occur with the Aux Tray? Go to step 12. Go to step 15 on page 140.
12. Check the paper path:a. Check the paper path between the Aux Tray input
and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295).
Does error code 220 occur?
Go to step 13. Problem solved. Verify theoriginal customer job printscorrectly.
13. Check the Aux Pick Up Solenoid:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1260 (see “Diagnostic Menu” on
page 284).
Did the Aux Pick Up Solenoid make a ‘click’ soundwhen this diagnostic was run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Trayv MCU PCB
Go to step 14 on page 140.
Chapter 1. Diagnosing Problems 139
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
14. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm
Repair/replace the Harness (J23- J231).
15. Does error code 220 occur with the Env Tray? If noEnv Tray is installed on this machine answer no.
Go to step 16. Go to step 20 on page 141.
16. Check the paper path:a. Check the paper path between the Envelope
Feeder and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 17. Problem solved. Verify theoriginal customer job printscorrectly.
17. Replace the Env Tray Asm:a. Replace the Env Tray Asm.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295).
Does error code 220 occur?
Replace the Env Tray Asm. Goto step 18 on page 141.
Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 140
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
18. Check the Env Connector -Female:a. Check the Env Connector -Female to make sure
that it is correctly connected and not damaged fromthe Interface PCB.
Is the connector in good condition?
Go to step 19. Repair/replace the EnvConnector - Female.
19. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm
Repair/replace the Harness (J23- J231).
20. Does the printer have an Option Paper Drawerinstalled (Tray 2)?
Go to step 25 on page 142. Go to step 21.
21. The error only occurs with Tray 1. Check the paperpath:a. Check the paper path between the 550-Sheet Tray
Asm (Tray 1) and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 22 on page 142. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 141
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
22. Check the Pick Clutch:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1200 (see “Diagnostic Menu” on
page 284).
Does the Pick Clutch make a ‘click’ sound whenthis diagnostic is run?
Go to step 24. Go to step 23.
23. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
24. Check the Feed Clutch:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1250 (see “Diagnostic Menu” on
page 284).
Does the Feed Clutch make a ‘click’ sound whenthis diagnostic is run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv 550-Sheet Tray Asmv Paper Handling Asmv MCU PCB
Go to step 23.
25. Does the printer have two Option Paper Drawersinstalled (Tray 2 and Tray 3)?
Go to step 34 on page 144. Go to step 26.
26. Does error code 220 occur with Tray 2? Go to step 27 on page 143. Go to step 21 on page 141.
Chapter 1. Diagnosing Problems 142
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
27. Does error code 220 also occur with Tray 1? Go to step 28. Go to step 30.
28. Check the paper path:a. Check the paper path between the 550-Sheet Tray
Asm (Tray 2) and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 29. Problem solved. Verify theoriginal customer job printscorrectly.
29. Check the Feed Clutch for the Feed Asm:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1250 (see “Diagnostic Menu” on
page 284).
Does the Feed Asm Feed Clutch make a ‘click’sound when this diagnostic is run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCBv Paper Handling Asm
Go to step 23 on page 142.
30. The error only occurs with Tray 2. Check the paperpath:a. Check the paper path between the 550-Sheet Tray
Asm (Tray 2) and the Registration Sensor.b. Replace any damaged component.c. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 31 on page 144. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 143
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
31. Check the 550-Sheet Tray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms between Tray 2
and Tray 1.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Go to step 32. Replace the 550-Sheet TrayAsm (in Tray 1).
32. Replace the Option Paper Drawer (Tray 2):a. Power off the printer.b. Replace the Option Paper Drawer.c. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur?
Install the original Option PaperDrawer. Go to step 33.
Problem solved. Verify theoriginal customer job printscorrectly.
33. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Size Sensor Asm
Repair/replace the Harness (J33- J331).
34. Does error code 220 occur with Tray 3? Go to step 35. Go to step 38 on page 145.
35. Does error code 221 also occur with Tray 2 or Tray1?
Go to step 39 on page 145. Go to step 36 on page 145.
Chapter 1. Diagnosing Problems 144
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
36. The error only occurs with Tray 3. Check the 550-SheetTray Asm (Tray 3):a. Switch the 550-Sheet Tray Asms between Tray 3
and Tray 2.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur with Tray 2?
Replace the 550-Sheet TrayAsm (in Tray 2).
Go to step 37.
37. Check the Option Paper Drawer (Tray 3):a. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur with Tray 2?
Replace the Option PaperDrawer (in Tray 2).
Go to step 33 on page 144.
38. Does error code 220 occur with Tray 2? Go to step 39. Go to step 21 on page 141.
39. Does error code 220 also occur with Tray 1? Go to step 28 on page 143. Go to step 40.
40. The error occurs with Tray 2. Check the 550-Sheet TrayAsm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2
becomes Tray 3.b. Print a Service Page from Tray 3 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur with Tray 3?
Replace the 550-Sheet TrayAsm (in Tray 3).
Go to step 41 on page 146.
Chapter 1. Diagnosing Problems 145
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
41. Check the Option Paper Drawer (Tray 2):a. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.b. Print a Service Page from Tray 3 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 220 occur with Tray 3?
Replace the Option PaperDrawer (in Tray 3).
Go to step 23 on page 142.
42. Check the Registration Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).
Does the Registration Clutch make a ‘click’ soundwhen this diagnostic is run?
Replace the MCU PCB. Go to step 43.
43. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 44 on page 147. Repair/replace the Harness (J23- J231).
Chapter 1. Diagnosing Problems 146
Table 31. Map 220: Paper Jam - Early Feed (continued)
Step Questions/Actions Yes No
44. Check the Harness (J43 - J432, J433):1. Power off the printer.2. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Clutch to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCB
Repair/replace the Harness (J43- J432, J433).
Chapter 1. Diagnosing Problems 147
MAP 221: Paper Jam - Late FeedSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Registration Sensor was activatedtoo late after the Feed Clutch was activated.
Registration Sensor 15%
Feed Roll Clutch 10%
Registration Actuator 7%
550-Sheet Tray Asm 7%
Aux Tray Asm 7%
Option Paper Drawer 7%
Paper Handling Asm 7%
Feed Asm 6%
Paper Size Sensor Asm 4%
Main Motor 4%
Gear Drive Asm 4%
Pick Clutch - Electric 4%
Feed PCB 3%
MCU PCB 3%
Paper Size PCB 3%
Interface PCB 2%
Aux Drive Gear 1%
Harness (J43 - J432, J433) 1%
Harness (J33 - J331) 1%
Harness (J51 - J511) 1%
Harness (J23 - J231) 1%
Chapter 1. Diagnosing Problems 148
Table 32. Map 221: Paper Jam - Late Feed
Step Questions/Actions Yes No
1. Check the No Paper Sensor:a. Remove all paper from the printer.b. Print a Service Page from all trays including the Aux
Tray (see “Printing the Service Page” on page 295).After each page, power off the printer and re-enterService Mode.You should get error code 011 when you print fromTray 1, Tray 2, or Tray 3. You should get error code012 when you print from the Aux Tray or theEnvelope Feeder.
Does error code 221 occur when printing from anytray?
The No-Paper Photo Sensor isnot working correctly.v If error code 221 occurred
from Tray 1, Tray 2, or Tray3, go to “MAP 011: Tray xEmpty” on page 89.
v If error code 221 occurredfrom the Aux tray or theEnvelope Feeder, go to “MAP012: (Aux/Env) Empty” onpage 97.
Go to step 2.
2. Check the paper:a. Reload all paper trays including the Aux Tray with
fresh, dry paper.b. Print a Service Page from all trays, including the
Aux Tray. See “Printing the Service Page” onpage 295).If you get error code 221 from any tray, power offthe printer, clear any paper jams, and re-enterService Mode to print from the next tray.
Does error code 221 occur from all trays?
Go to step 3 on page 150. Go to step 11 on page 153.
Chapter 1. Diagnosing Problems 149
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
3. Check the paper path:a. Check the paper path from all trays to the
Registration Sensor for blockage or damaged parts.Especially check between the Center RegistrationChute and Lower Registration Chute in the PaperHandling Asm.
b. Replace any damaged part.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur?
Go to step 4. Problem solved. Verify theoriginal customer job printscorrectly.
4. Check the Registration Sensor Actuator:a. Check the Registration Sensor Actuator and ensure
that it is not damaged and working correctly.b. Clean the Registration Sensor.
Is the Registration Sensor Actuator intact andworking correctly?
Go to step 5. Repair/replace the RegistrationSensor Actuator.
5. Check the Registration Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Open the Front Cover.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Move the Registration Actuator to activate the
Registration Sensor.
Did the Diagnostic display “Sensor/Switch OK”when the Registration Sensor was actuated?
Go to step 8 on page 151. Go to step 6 on page 151.
Chapter 1. Diagnosing Problems 150
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
6. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 7. Repair/replace the Harness (J23- J231).
7. Check the Harness (J43 - J432, J433):a. Power off the printer.b. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Sensor to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCB
Repair/replace the Harness (J43- J432, J433).
8. Check the Main Motor:a. Open the Front Cover.b. Remove the Toner Cartridge.c. Close the Front Cover.d. Enter Service Mode (see “Accessing Service Mode”
on page 280.)e. Run Diagnostic 1100 (see “Diagnostic Menu” on
page 284).
Do all gears rotate correctly?
Go to step 41 on page 160. Go to step 9 on page 152.
Chapter 1. Diagnosing Problems 151
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
9. Check the Main Motor:a. Power off the printer.b. Remove the Main Motor, leaving the Harness (J29 -
J291) attached to the MCU PCB.
DANGER
<1-10> Hazardous voltages are present. Donot touch the pins or the sockets of the powerreceptacle. Do not attempt to measurevoltages or make any other checks at thepower receptacle, the power cord, or thepower supply input before you perform thePower-Receptacle Safety-Check. Make thesechecks only if you are a qualified servicerepresentative or a qualified electrician.Inform the customer if the voltages or otherchecks are not within the correct operatingrange. Do not continue until the customer hasfixed the problem.
c. Enter Service Mode (see “Accessing Service Mode”on page 280.)
d. Run Diagnostic 1100 (see “Diagnostic Menu” onpage 284).
Does the Main Motor rotate correctly?
Go to step 10 on page 153. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Main Motorv MCU PCB
Chapter 1. Diagnosing Problems 152
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
10. Check the Gear Drive:a. Power off the printer.b. Check for damage by manually rotating the Main
Motor and watching the Gear Drive Asm.
Does the Gear Drive Asm function correctly?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Handling Asm
Repair/replace the Gear DriveAsm.
11. Does error code 221 occur from the Aux Tray? Go to step 12. Go to step 15 on page 154.
12. Check the paper path:a. Power off the printer.b. Check the paper path between the Aux Tray input
and the Registration Sensor for foreign material ordamaged parts.
c. Replace any damaged part.d. Print a Service Page from the Aux Tray to the Main
Output Bin (see “Printing the Service Page” onpage 295).
Does error code 221 occur?
Go to step 13. Problem solved. Verify theoriginal customer job printscorrectly.
13. Check the Aux Pick Up Solenoid:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1260 (see “Diagnostic Menu” on
page 284).
Did the Aux Pick Up Solenoid make a ‘click’ soundwhen this diagnostic was run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv Aux Drive Gearv Gear Drive Asmv MCU PCBv Interface PCB
Go to step 14 on page 154.
Chapter 1. Diagnosing Problems 153
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
14. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Aux Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm
Repair/replace the Harness (J23- J231).
15. Does error code 221 occur from the Env Tray? If noEnv Tray is installed on this machine, answer no.
Go to step 16. Go to step 19 on page 155.
16. Check the paper path:a. Power off the printer.b. Check the paper path between the Env Tray input
and the Registration Sensor for foreign material ordamaged parts.
c. Replace any damaged part.d. Print a Service Page from the envelope feeder to
the Main Output Bin (see “Printing the ServicePage” on page 295.)
Does error code 221 occur?
Go to step 17. Problem solved. Verify theoriginal customer job printscorrectly.
17. Check the Env Connector -Female:a. Check the Env Connector -Female to make sure
that it is correctly connected and not damaged fromthe Interface PCB.
Is the connector in good condition?
Go to step 18 on page 155. Repair/replace the EnvConnector - Female.
Chapter 1. Diagnosing Problems 154
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
18. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Paper Handling Asm
Repair/replace the Harness (J23- J231).
19. Does the printer have a second paper tray (Tray 2)installed?
Go to step 24 on page 156. Go to step 20.
20. The error only occurs from Tray 1. Check the paperpath:a. Power off the printer.b. Check the paper path between the 550-Sheet Tray
Asm (Tray 1) and the Registration Sensor forforeign material or damaged parts.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur from Tray 1?
Go to step 21 on page 156. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 155
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
21. Check the Pick Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1200 (see “Diagnostic Menu” on
page 284).
Does the Pick Clutch make a ‘click’ sound whenthis diagnostic is run?
Go to step 23. Go to step 22.
22. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCB
Repair/replace the Harness (J33- J331).
23. Check the Feed Clutch:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1250 (see “Diagnostic Menu” on
page 284).Note: Diagnostic 1250 actuates the feed clutchesfor all trays (Tray 1, Tray 2, and Tray 3). Check onlyfor the Tray 1 Feed Clutch.
Does the Tray 1 Feed Clutch make a ‘click’ soundwhen this diagnostic is run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv 550-Sheet Tray Asmv Gear Drive Asmv Paper Handling Asmv MCU PCB
Go to step 22.
24. Does the printer have two Option Paper Drawersinstalled (Tray 2 and Tray 3)?
Go to step 32 on page 158. Go to step 25 on page 157.
Chapter 1. Diagnosing Problems 156
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
25. Does error code 221 occur with Tray 2? Go to step 26. Go to step 20 on page 155.
26. Does error code 221 also occur with Tray 1? Go to step 27. Go to step 29 on page 158.
27. Check the paper path:a. Power off the printer.b. Check the paper path from the 550-Sheet Tray Asm
(Tray 2) to the Registration Sensor for foreignmaterial or damaged parts.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur?
Go to step 28. Problem solved. Verify theoriginal customer job printscorrectly.
28. Check the Feed Clutch for the Feed Asm:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1250 (see “Diagnostic Menu” on
page 284).Note: Diagnostic 1250 actuates the feed clutchesfor all trays (Tray 1, Tray 2, and Tray 3). Check onlyfor the Tray 2 Feed Clutch.
Does the Tray 2 Feed Asm Feed Clutch make a‘click’ sound when this diagnostic is run?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Feed Asmv Paper Size Sensor Asmv MCU PCBv Paper Handling Asm
Go to step 22 on page 156.
Chapter 1. Diagnosing Problems 157
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
29. The error only occurs from Tray 2. Check the paperpath:a. Check the paper path from the 550-Sheet Tray Asm
(Tray 2) to the Registration Sensor for foreignmaterial or damaged parts.
b. Replace any damaged part.c. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur?
Go to step 30. Problem solved. Verify theoriginal customer job printscorrectly.
30. Check the 550-Sheet Tray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2
becomes Tray 1.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur?
Go to step 31. Replace the 550-Sheet TrayAsm (in Tray 1).
31. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Option Paper Drawer (Tray 2)v MCU PCBv Paper Size Sensor Asm
Repair/replace the Harness (J33- J331).
32. Does error code 221 occur from Tray 3? Go to step 33. Go to step 36 on page 159.
33. Does error code 221 also occur from Tray 2 or Tray1?
Go to step 37 on page 159. Go to step 34 on page 159.
Chapter 1. Diagnosing Problems 158
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
34. The error only occurs from Tray 3. Check the 550-SheetTray Asm (Tray 3):a. Switch the 550-Sheet Tray Asms so that Tray 3
becomes Tray 2.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur from Tray 2?
Replace the 550-Sheet TrayAsm (in Tray 2).
Go to step 35.
35. Check the Option Paper Drawer (Tray 3):a. Switch the Option Paper Drawers so that Tray 3
becomes Tray 2.b. Print a Service Page from Tray 2 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur from Tray 2?
Replace the Option PaperDrawer (in Tray 2).
Go to step 40 on page 160.
36. Does error code 221 occur from Tray 2? Go to step 37. Go to step 20 on page 155.
37. Does error code 221 also occur from Tray 1? Go to step 27 on page 157. Go to step 38.
38. The error occurs from Tray 2. Check the 550-SheetTray Asm (Tray 2):a. Switch the 550-Sheet Tray Asms so that Tray 2
becomes Tray 3.b. Print a Service Page from Tray 3 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur from Tray 3?
Replace the 550-Sheet TrayAsm (in Tray 3).
Go to step 39 on page 160.
Chapter 1. Diagnosing Problems 159
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
39. Check the Option Paper Drawer (Tray 2):a. Switch the Option Paper Drawers so that Tray 2
becomes Tray 3.b. Print a Service Page from Tray 3 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 221 occur from Tray 3?
Replace the Option PaperDrawer (in Tray 3).
Go to step 22 on page 156.
40. Check the Harness (J33 - J331):a. Power off the printer.b. Check the Harness (J33 - J331) from the MCU PCB
to the Paper Size Sensor Asm to make sure that itis correctly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Paper Size Sensor Asm
Repair/replace the Harness (J33- J331).
41. Check the Registration Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).
Does the Registration Clutch make a ‘click’ soundwhen this diagnostic is run?
Replace the MCU PCB. Go to step 42 on page 161.
Chapter 1. Diagnosing Problems 160
Table 32. Map 221: Paper Jam - Late Feed (continued)
Step Questions/Actions Yes No
42. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 43. Repair/replace the Harness (J23- J231).
43. Check the Harness (J43 - J432, J433):1. Power off the printer.2. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Clutch to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCB
Repair/replace the Harness (J43- J432, J433).
Chapter 1. Diagnosing Problems 161
MAP 230: Paper Jam - Late ExitSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that the Registration Sensor wasactivated at power on.
Fuser Asm 120 v, Fuser Asm 230 v 35%
Registration Clutch - Electric 30%
Toner Cartridge 15%
Paper Handling Asm 6%
BTR Support Asm 6%
Gear Drive Asm 4%
MCU PCB 2%
Interface PCB 1%
Harness (J27, J11, J262-J271) 1%
Harness (J23 - J231) 1%
Harness (J43 - J432, J433) 1%
Table 33. Map 230: Paper Jam - Late Exit
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295).
Does error code 230 occur?
Go to step 2 on page 163. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
Chapter 1. Diagnosing Problems 162
Table 33. Map 230: Paper Jam - Late Exit (continued)
Step Questions/Actions Yes No
2. Check the paper path:a. Check the paper path from the Registration Sensor
to the Fuser Asm for fragments of paper or otherforeign material that could block the paper path.
b. Replace any damaged part.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 230 occur?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Check the Registration Clutch:a. Power off the printer.b. Enter Service Mode (see “Accessing Service Mode”
on page 280.)c. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).
Does the Registration Clutch make a ‘click’ soundwhen this diagnostic is run?
Go to step 4. Go to step 11 on page 165.
4. Check the Registration Sensor:a. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).b. Activate the registration sensor.
Does the Registration Sensor work correctly?
Go to step 5 on page 164. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Sensorv MCU PCBv Interface PCBv Harness (J23 - J231)v Harness (J43 - J432, J433)
Chapter 1. Diagnosing Problems 163
Table 33. Map 230: Paper Jam - Late Exit (continued)
Step Questions/Actions Yes No
5. Replace the Fuser Asm 120 v, Fuser Asm 230 v:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 230 occur?
Go to step 6. The problem is solved. Verifythe original customer job printscorrectly.
6. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 230 occur?
Go to step 7. The problem is solved. Verifythe original customer job printscorrectly.
7. Check the Gear Drive:a. Power off the printer.b. Check for damage in the Gear Drive Asm. by
rotating the Main Motor.
Does the Gear Drive Asm function correctly?
Go to step 8 on page 165. Repair/replace the Gear DriveAsm.
Chapter 1. Diagnosing Problems 164
Table 33. Map 230: Paper Jam - Late Exit (continued)
Step Questions/Actions Yes No
8. Check the Harness (J27 - J271):a. Power off the printer.b. Check the Harness (J27 - J271) from the MCU PCB
to the Fuser Asm to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 9. Repair/replace the Harness(J27, J11, J262-J271).
9. Check the Paper Handling Asm:a. Inspect the Paper Handling Asm for damaged parts,
especially the registration rollers.
Is the Paper Handling Asm damaged?
Replace the Paper HandlingAsm.
Go to step 10.
10. Check the BTR Support Asm:a. Inspect the BTR Support Asm for damaged parts,
especially the Bias Transfer Roll.
Is the BTR Support Asm damaged?
Replace the BTR Support Asm. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Aux Tray Asmv Env Tray Asm (if installed)
11. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 12 on page 166. Repair/replace the Harness (J23- J231).
Chapter 1. Diagnosing Problems 165
Table 33. Map 230: Paper Jam - Late Exit (continued)
Step Questions/Actions Yes No
12. Check the Harness (J43 - J432, J433):1. Power off the printer.2. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Clutch to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCB
Repair/replace the Harness (J43- J432, J433).
Chapter 1. Diagnosing Problems 166
MAP 232: Paper Jam - Exit OnSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Exit Sensor is activated at anincorrect time or while not printing.
Fuser Asm 120 v, Fuser Asm 230 v 85%
MCU PCB 5%
Harness (J27, J11, J262-J271) 5%
Interface PCB 3%
Paper Handling Asm 2%
Table 34. Map 232: Paper Jam - Exit On
Step Questions/Actions Yes No
1. Check the Exit Sensor:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Check the paper path in the Fuser Asm for
obstructions.c. Open the paper jam customer access area at the
back of the fuser and check the Exit Sensor.
Is the Fuser and Exit Sensor clear of obstructions?
Go to step 2 on page 168. Clear the obstruction or replacethe Fuser.
Chapter 1. Diagnosing Problems 167
Table 34. Map 232: Paper Jam - Exit On (continued)
Step Questions/Actions Yes No
2. Check the Exit Sensor Actuator:a. Power off the printer.b. Manually check the Exit Sensor Actuator and ensure
that it is not damaged and working correctly.c. Clean the Exit Sensor.
Is the Exit Sensor Actuator intact and workingcorrectly?
Go to step 3 on page 169. Repair/replace the Fuser Asm120 v, Fuser Asm 230 v.
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutes forparts in this area to coolbefore handling.
Chapter 1. Diagnosing Problems 168
Table 34. Map 232: Paper Jam - Exit On (continued)
Step Questions/Actions Yes No
3. Check the Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Open the Rear Cover and remove the Duplex Asm,
if it is installed.c. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).d. Open the paper jam customer access area at the
back of the fuser and actuate the Exit Sensor byblocking the sensor.
CAUTION:<2-43> High Temperature; switch off the printerand allow at least 30 minutes for parts in thisarea to cool before handling.
Did the Diagnostic display “Sensor/Switch OK”when the Exit Sensor was blocked?
Repair/replace the MCU PCB Go to step 4 on page 170.
Chapter 1. Diagnosing Problems 169
Table 34. Map 232: Paper Jam - Exit On (continued)
Step Questions/Actions Yes No
4. Check the Harness (J27 - J271):1. Power off the printer.2. Check the Harness (J27 - J271) from the MCU PCB
to the Fuser Asm to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v Paper Handling Asmv MCU PCBv Interface PCBv Harness (J27, J11,
J262-J271)
Repair/replace the Harness(J27, J11, J262-J271).
Chapter 1. Diagnosing Problems 170
MAP 250: Paper Jam - Duplex Early RegistrationSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Registration Sensor was activatedtoo early after the Duplex Sensor activation.
Duplex Asm 95%
Paper Handling Asm 3%
MCU PCB 1%
Harness (J34 - J341) (see “Harness (J34-P341)” onpage 403)
1%
Table 35. Map 250: Paper Jam - Duplex Early Registration
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper in all trays, and reload with
fresh, dry paper.b. Run a test print.
Does error code 250 occur?
Go to step 2 on page 172. The paper supply could be theproblem. Check the size andtype of the customer’s paperwith the specifications. If thepaper is within specification, usethe customer’s paper and repeatthis step.
Chapter 1. Diagnosing Problems 171
Table 35. Map 250: Paper Jam - Duplex Early Registration (continued)
Step Questions/Actions Yes No
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Duplex Asm to the
Registration Sensor for fragments of paper or otherforeign material that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 250 occur?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Check the Harness (J34 - J341):1. Power off the printer.2. Check the Harness (J34 - J341) from the MCU PCB
to the Duplex Asm to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Paper Handling Asm
Repair/replace the Harness (J34- J341).
Chapter 1. Diagnosing Problems 172
MAP 253: Paper Jam - Late DuplexSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Duplex Sensor was never activatedafter the Exit Sensor was activated.
Duplex Asm 80%
Exit Asm 18%
MCU PCB 1%
Harness (J34 - J341) 1%
Table 36. Map 253: Paper Jam - Late Duplex
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.Note: The optional Face-up Output Bin must beclosed for duplex printing to occur. If the Face-upOutput Bin is open during duplex printing, errorcode 049 should occur.
b. Print a Service Page from Tray 1 to the Main OutputBin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 253 occur?
Go to step 2 on page 174. The paper supply could be theproblem. Check the size andtype of the customer’s paperwith the specifications. If thepaper is within specification, usethe customer’s paper and repeatthis step.
Chapter 1. Diagnosing Problems 173
Table 36. Map 253: Paper Jam - Late Duplex (continued)
Step Questions/Actions Yes No
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Exit Sensor in the
Fuser Asm to the Duplex Asm for damaged parts orfragments of paper or other foreign material thatcould block the paper path.
c. Remove the Duplex Asm.d. Check the Duplex Asm, especially near the Duplex
Paper Photo Sensor, for foreign material ordamaged parts. Make sure the Duplex Asm isworking correctly.
e. Replace any damaged part.f. Print a Service Page from Tray 1 to the Main Output
Bin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 253 occur?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Check the Harness (J34 - P341):1. Power off the printer.2. Check the Harness (J34 - P341) from the MCU
PCB to the Duplex Asm to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Exit Asm
Repair/replace the Harness (J34- P341).
Chapter 1. Diagnosing Problems 174
MAP 254: Paper Jam - Duplex OnSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Duplex Sensor was activated at anincorrect time (for example, at power on) or was not activatedin the specified time after the Exit Sensor was activated.
Duplex Asm 98%
MCU PCB 1%
Harness (J34 - P341) 1%
Table 37. Map 254: Paper Jam - Duplex On
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.Note: The optional Face-up Output Bin must beclosed for duplex printing to occur. If the Face-upOutput Bin is open during duplex printing, errorcode 049 should occur.
b. Print a Service Page from Tray 1 to the Main OutputBin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 254 occur?
Go to step 2 on page 176. The paper supply could be theproblem. Check the size andtype of the customer’s paperwith the specifications. If thepaper is within specification, usethe customer’s paper and repeatthis step.
Chapter 1. Diagnosing Problems 175
Table 37. Map 254: Paper Jam - Duplex On (continued)
Step Questions/Actions Yes No
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Exit Sensor in the
Fuser Asm to the Duplex Asm for damaged partsand for fragments of paper or other foreignmaterials that could block the paper path.
c. Remove the Duplex Asm.d. Check the Duplex Asm, especially in the jam
clearance customer access area, for foreignmaterial or damaged parts. Make sure the DuplexAsm is working correctly.
e. Replace any damaged parts.f. Print a Service Page from Tray 1 to the Main Output
Bin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 254 occur?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Check the Harness (J34 - P341):1. Power off the printer.2. Check the Harness (J34 - P341) from the MCU
PCB to the Duplex Asm to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB
Repair/replace the Harness (J34- P341).
Chapter 1. Diagnosing Problems 176
MAP 255: Paper Jam - Duplex Late RegistrationSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Registration Sensor was neveractivated after the Duplex Sensor activation.
Duplex Asm 95%
Paper Handling Asm 3%
MCU PCB 1%
Harness (J34 - P341) 1%
Table 38. Map 255: Paper Jam - Duplex Late Registration
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output
Bin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 255 occur?
Go to step 2 on page 178. The paper supply could be theproblem. Check the size andtype of the customer’s paperwith the specifications. If thepaper is within specification, usethe customer’s paper and repeatthis step.
Chapter 1. Diagnosing Problems 177
Table 38. Map 255: Paper Jam - Duplex Late Registration (continued)
Step Questions/Actions Yes No
2. Check the paper path:a. Power off the printer.b. Remove the Duplex Asm.c. Check the paper path from the Duplex Asm to the
Registration Sensor for fragments of paper or otherforeign materials that could block the paper path.
d. Open the jam clearance customer access area inthe Duplex Asm and check for foreign material ordamaged parts.
e. Replace any damaged part.f. Print a Service Page from Tray 1 to the Main Output
Bin in duplex mode (see “Printing the Service Page”on page 295.)
Does error code 255 occur?
Go to step 3. Problem solved. Verify theoriginal customer job printscorrectly.
3. Check the Harness (J34 - P341):1. Power off the printer.2. Check the Harness (J34 - P341) from the MCU
PCB to the Duplex Asm to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCBv Paper Handling Asm
Repair/replace the Harness (J34- P341).
Chapter 1. Diagnosing Problems 178
MAP 261: Paper Jam - Late OffsetSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Offset Exit Sensor was neveractivated after the Exit Sensor was when printing to theOffset Asm.
Offset Asm 90%
Exit Asm 5%
Fuser Asm 120 v, Fuser Asm 230 v 3%
MCU PCB 1%
Harness (J35 - J351) 1%
Table 39. Map 261: Paper Jam - Late Offset
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Offset Bin
(see “Printing the Service Page” on page 295.)
Does error code 261 occur?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Fuser Asm to the
Offset Exit for fragments of paper or other foreignmaterial that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Offset Bin
(see “Printing the Service Page” on page 295.)
Does error code 261 occur?
Go to step 3 on page 180. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 179
Table 39. Map 261: Paper Jam - Late Offset (continued)
Step Questions/Actions Yes No
3. Check the Offset Exit Sensor Actuator:a. Power off the printer.b. Check the Offset Exit Sensor Actuator and ensure
that it is not damaged and working correctly.c. Clean the Offset Exit Sensor.
Is the Offset Exit Sensor Actuator intact andworking correctly?
Go to step 4. Repair/replace the Offset ExitSensor Actuator.
4. Check the Offset Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).c. Actuate the Offset Exit Sensor by lifting the Offset
Exit Sensor Actuator.
Did the Diagnostic display “Sensor/Switch OK”when the Offset Exit Sensor was blocked?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asmv Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v Exit Asm
Go to step 5 on page 181.
Chapter 1. Diagnosing Problems 180
Table 39. Map 261: Paper Jam - Late Offset (continued)
Step Questions/Actions Yes No
5. Check the Harness (J35 - J351):1. Power off the printer.2. Check the Harness (J35 - J351) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB
Repair/replace the Harness (J35- J351).
Chapter 1. Diagnosing Problems 181
MAP 262: Paper Jam - Offset OnSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Offset Exit Sensor was activated atthe wrong time.
Offset Asm 95%
MCU PCB 4%
Harness (J35 - J351) 1%
Table 40. Map 262: Paper Jam - Offset On
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Offset Bin
(see “Printing the Service Page” on page 295.)
Does error code 262 occur?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Fuser Asm to the
Offset Exit for fragments of paper or other foreignmaterial that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Offset Bin
(see “Printing the Service Page” on page 295.)
Does error code 262 occur?
Go to step 3 on page 183. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 182
Table 40. Map 262: Paper Jam - Offset On (continued)
Step Questions/Actions Yes No
3. Check the Offset Exit Sensor Actuator:a. Power off the printer.b. Check the Offset Exit Sensor Actuator and ensure
that it is not damaged and working correctly.c. Clean the Offset Exit Sensor.
Is the Offset Exit Sensor Actuator intact andworking correctly?
Go to step 4. Repair/replace the Offset ExitSensor Actuator.
4. Check the Offset Exit Sensor:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1020 (see “Diagnostic Menu” on
page 284).c. Actuate the Offset Exit Sensor by lifting the Offset
Exit Sensor Actuator.
Did the Diagnostic display “Sensor/Switch OK”when the Offset Exit Sensor was blocked?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asm
Go to step 5.
5. Check the Harness (J35 - J351):1. Power off the printer.2. Check the Harness (J35 - J351) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Offset Asm
Repair/replace the Harness (J35- J351).
Chapter 1. Diagnosing Problems 183
MAP 272: Paper Jam - Exit On (Specific)Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Exit Sensor in the Fuser Asm wasactivated but did not deactivate within the specified time. Thiserror is the same as Error 276, but occurs from all papersexcept custom or universal.
Fuser Asm 120 v, Fuser Asm 230 v 35%
Registration Clutch - Electric 30%
Exit Motor 20%
Toner Cartridge 5%
Paper Handling Asm 2%
BTR Support Asm 2%
Gear Drive Asm 1%
MCU PCB 1%
Interface PCB 1%
Harness (J27, J11, J262-J271) 1%
Harness (J23 - J231) 1%
Harness (J43 - J432, J433) 1%
Exit Roll 1 1%
Exit Roll 2 1%
Exit Roll 3 1%
Chapter 1. Diagnosing Problems 184
Table 41. Map 272: Paper Jam - Exit On (Specific)
Step Questions/Actions Yes No
1. Check the paper:Note: This error can be generated by a brokenfull-stack sensor that causes paper to jam and block theExit Sensor in the Fuser. If the main bin is full of paperwhen error 272 occurs, go to “MAP 031: Unload PaperFrom Main Output Bin” on page 113. If the Offset Bin isfull of paper when error 272 occurs, go to “MAP 035:Unload Paper From Offset Bin” on page 115.a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 272 occur?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Registration Sensor
to the Exit Asm for fragments of paper or otherforeign material that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 272 occur?
Go to step 3 on page 186. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 185
Table 41. Map 272: Paper Jam - Exit On (Specific) (continued)
Step Questions/Actions Yes No
3. Check the Registration Clutch:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).
Does the Registration Clutch work correctly (make a‘click’ sound) when Diagnostic 1280 is run?
Go to step 4. Go to step 10 on page 188.
4. Replace the Fuser Asm 120 v, Fuser Asm 230 v:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 272 occur?
Go to step 5. The problem is solved. Verifythe original customer job printscorrectly.
5. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 272 occur?
Go to step 6 on page 187. The problem is solved. Verifythe original customer job printscorrectly.
Chapter 1. Diagnosing Problems 186
Table 41. Map 272: Paper Jam - Exit On (Specific) (continued)
Step Questions/Actions Yes No
6. Check the Gear Drive:a. Power off the printer.b. Open the Front Cover and remove the Toner
Cartridge.c. Open the Rear Cover.d. Check for damage in the Gear Drive Asm by
manually rotating the Main Motor clockwise andwatching the Gear Drive Asm.Note: The Gear Drive Asm will not engage thefuser gears if the front cover is open.
e. Check the gear that engages the gear on the FuserAsm to ensure that it is turning correctly.
Does the Gear Drive Asm function correctly?
Go to step 7. Repair/replace the Gear DriveAsm.
7. Check the Harness (J27, J11, J262-J271):a. Power off the printer.b. Check the Harness (J27, J11, J262-J271) from the
MCU PCB to the Fuser Asm to make sure that it iscorrectly connected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 8. Repair/replace the Harness(J27, J11, J262-J271).
8. Check the Paper Handling Asm:a. Inspect the Paper Handling Asm for damaged parts,
especially the registration rollers.
Is the Paper Handling Asm free of damage?
Go to step 9 on page 188. Replace the Paper HandlingAsm.
Chapter 1. Diagnosing Problems 187
Table 41. Map 272: Paper Jam - Exit On (Specific) (continued)
Step Questions/Actions Yes No
9. Check the BTR Support Asm:a. Remove the Bias Transfer Roll.b. Inspect the BTR Support Asm and the Bias Transfer
Roll for damaged parts
Is the BTR Support Asm damaged?
Replace the BTR Support Asm. Go to step 12 on page 189.
10. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
c. Check for continuity between the following pins:v J23-9 to J231-8
Is the harness free of damage and does it havecontinuity?
Go to step 11. Repair/replace the Harness (J23- J231).
11. Check the Harness (J43 - J432, J433):a. Power off the printer.b. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Sensor to makesure that it is correctly connected and not damaged.
c. Remove the Paper Handling Asm. Then Check forcontinuity between the following pins:v J43-2 to J433-1v J43-1 to J433-4
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCBv 550-Sheet Tray Asmv Feed Asm
Repair/replace the Harness (J43- J432, J433).
Chapter 1. Diagnosing Problems 188
Table 41. Map 272: Paper Jam - Exit On (Specific) (continued)
Step Questions/Actions Yes No
12. Check the Exit Rolls:a. Power off the printer.b. Open the Rear Cover.c. Manually turn the exit gears to ensure the exit gears
and rolls are working correctly.
Are the Exit Gears and Rolls working correctly?
Go to step 13. Replace the failing exit gear orexit roll.v Exit Roll 1v Exit Roll 2v Exit Roll 3
13. Check the Exit Motor:1. Power off the printer.2. Ensure that the harness from the Exit Motor to
P/J32 on the MCU PCB is correctly connected.3. Enter Service Mode (see “Accessing Service Mode”
on page 280.)4. Run Diagnostic 1150 (see “Diagnostic Menu” on
page 284).
Does the Exit Motor rotate and operate correctlywhen running this diagnostic?
Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Exit Motorv MCU PCB
Chapter 1. Diagnosing Problems 189
MAP 275: Paper Jam - Early Exit OffSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that the Exit Sensor in the Fuser Asmbecame deactivated too early after the paper entered theFuser.
Fuser Asm 120 v, Fuser Asm 230 v 60%
Gear Drive Asm 24%
MCU PCB 15%
Harness (J27, J11, J262-J271) 1%
Table 42. Map 275: Paper Jam - Early Exit Off
Step Questions/Actions Yes No
1. Check the paper:a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 275 occur?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Fuser Asm to the
Exit Asm for fragments of paper or other foreignmaterial that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 275 occur?
Go to step 3 on page 191. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 190
Table 42. Map 275: Paper Jam - Early Exit Off (continued)
Step Questions/Actions Yes No
3. Check the Gear Drive:a. Power off the printer.b. Remove the Gear Drive Asm.c. Check for damage by rotating the gears in the Gear
Drive Asm.
Does the Gear Drive Asm function correctly?
Go to step 4. Repair/replace the Gear DriveAsm.
4. Check the Harness (J27 - J271):1. Power off the printer.2. Check the Harness (J27 - J271) from the MCU PCB
to the Fuser Asm to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v MCU PCB
Repair/replace the Harness(J27, J11, J262-J271).
Chapter 1. Diagnosing Problems 191
MAP 276: Paper Jam - Exit On (Universal)Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Exit Sensor in the Fuser Asm wasactivated but did not deactivate within the specified time. Thiserror is the same as Error 272, but occurs only with customor universal paper sizes.
Fuser Asm 120 v, Fuser Asm 230 v 35%
Registration Clutch - Electric 30%
Exit Motor 20%
Toner Cartridge 5%
Paper Handling Asm 2%
BTR Support Asm 2%
Gear Drive Asm 1%
MCU PCB 1%
Interface PCB 1%
Harness (J27, J11, J262-J271) 1%
Harness (J23 - J231) 1%
Harness (J43 - J432, J433) 1%
Chapter 1. Diagnosing Problems 192
Table 43. Map 276: Paper Jam - Exit On (Universal)
Step Questions/Actions Yes No
1. Check the paper:Note: This error can be generated by a brokenfull-stack sensor that causes paper to jam and block theExit Sensor in the Fuser. If the main bin is full of paperwhen error 276 occurs, go to “MAP 031: Unload PaperFrom Main Output Bin” on page 113. If the Offset Bin isfull of paper when error 276 occurs, go to “MAP 035:Unload Paper From Offset Bin” on page 115.a. Remove the paper from all trays, and reload with
fresh, dry paper.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 276 occur?
Go to step 2. The paper supply could be theproblem. Check the size andtype of the customer’s paper todetermine if it is withinspecifications.
2. Check the paper path:a. Power off the printer.b. Check the paper path from the Registration Sensor
to the Exit Asm for fragments of paper or otherforeign material that could block the paper path.
c. Replace any damaged part.d. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 276 occur?
Go to step 3 on page 194. Problem solved. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 193
Table 43. Map 276: Paper Jam - Exit On (Universal) (continued)
Step Questions/Actions Yes No
3. Check the Registration Clutch:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).
Does the Registration Clutch work correctly (make a‘click’ sound) when this diagnostic is run?
Go to step 4. Go to step 10 on page 196.
4. Replace the Fuser Asm 120 v, Fuser Asm 230 v:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 276 occur?
Go to step 5. The problem is solved. Verifythe original customer job printscorrectly.
5. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does error code 276 occur?
Go to step 6 on page 195. The problem is solved. Verifythe original customer job printscorrectly.
Chapter 1. Diagnosing Problems 194
Table 43. Map 276: Paper Jam - Exit On (Universal) (continued)
Step Questions/Actions Yes No
6. Check the Gear Drive:a. Power off the printer.b. Open the Front Cover and remove the Toner
Cartridge.c. Check for damage by manually rotating the Main
Motor clockwise and watching the Gear Drive Asm.d. Check the gear that engages the gear on the Fuser
Asm to ensure that it is turning correctly
Does the Gear Drive Asm function correctly?
Go to step 7. Repair/replace the Gear DriveAsm.
7. Check the Harness (J27 - J271):a. Power off the printer.b. Check the Harness (J27 - J271) from the MCU PCB
to the Fuser Asm to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 8. Repair/replace the Harness(J27, J11, J262-J271).
8. Check the Paper Handling Asm:a. Inspect the Paper Handling Asm for damaged parts,
especially the registration rollers.
Is the Paper Handling Asm damaged?
Replace the Paper HandlingAsm.
Go to step 9.
9. Check the BTR Support Asm:a. Remove the Bias Transfer Roll.b. Inspect the BTR Support Asm and the Bias Transfer
Roll for damaged parts
Is the BTR Support Asm damaged?
Replace the BTR Support Asm. Go to step 12 on page 196.
Chapter 1. Diagnosing Problems 195
Table 43. Map 276: Paper Jam - Exit On (Universal) (continued)
Step Questions/Actions Yes No
10. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Go to step 11. Repair/replace the Harness (J23- J231).
11. Check the Harness (J43 - J432, J433):a. Power off the printer.b. Check the Harness (J43 - J432, J433) from the
Interface PCB and the Registration Sensor to makesure that it is correctly connected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Registration Clutch - Electricv MCU PCBv Interface PCBv 550-Sheet Tray Asmv Feed Asm
Repair/replace the Harness (J43- J432, J433).
12. Check the Exit Motor:1. Enter Service Mode (see “Accessing Service Mode”
on page 280.)2. Run Diagnostic 1150 (see “Diagnostic Menu” on
page 284).
Does the Exit Motor rotate and operate correctlywhen running this diagnostic?
Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Exit Motorv MCU PCB
Chapter 1. Diagnosing Problems 196
MAP 430: Motor ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a problem with the Main Motor. Main Motor 45%
LVPS 120V, LVPS 230V 10%
Gear Drive Asm 5%
Toner Cartridge 5%
Fuser Asm 120 v, Fuser Asm 230 v 5%
Feed Asm 5%
Paper Handling Asm 5%
Aux Tray 5%
Env Tray Asm 5%
Option Paper Drawer 5%
MCU PCB 4%
Harness (J28 - J281) 1%
Chapter 1. Diagnosing Problems 197
Table 44. Map 430: Motor Error
Step Questions/Actions Yes No
1. Check the Main Motor:
a. Enter Service Mode (see “Accessing Service Mode” onpage 280.)
b. Run diagnostic 1100 (see “Diagnostic Menu” on page 284).Note: If you get error code 430 in the Diagnostic Menu andyou are unable to run the diagnostic, go to step 2 onpage 199.
Does the Main Motor turn continuously while the diagnosticis running?
Replace the MCU PCB. Go to step 2 on page 199.
Chapter 1. Diagnosing Problems 198
Table 44. Map 430: Motor Error (continued)
Step Questions/Actions Yes No
2. Check the Main Motor:
DANGER
<1-10> Hazardous voltages are present. Do not touch thepins or the sockets of the power receptacle. Do notattempt to measure voltages or make any other checksat the power receptacle, the power cord, or the powersupply input before you perform the Power-ReceptacleSafety-Check. Make these checks only if you are aqualified service representative or a qualified electrician.Inform the customer if the voltages or other checks arenot within the correct operating range. Do not continueuntil the customer has fixed the problem.
a. Power off the printer.
b. Remove the Main Motor, leaving the Harness (J29 - J291)attached to the MCU PCB.
c. Power on the printer.
d. Enter Service Mode (see “Accessing Service Mode” onpage 280.)
e. Run diagnostic 1100 (see “Diagnostic Menu” on page 284).
f. If you get error code 430 in the Diagnostic Menu and youare unable to run the diagnostic, answer no to this step.
Does the Main Motor turn continuously while the diagnosticis running?
Go to step 3 on page 200. Repair/replace the following, oneat a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)
v Main Motor
v MCU PCB
Chapter 1. Diagnosing Problems 199
Table 44. Map 430: Motor Error (continued)
Step Questions/Actions Yes No
3. Check the Gear Drive:
a. Power off the printer.
b. Re-install the Main Motor.
c. Remove the Envelope Tray Asm if it is installed.
d. Remove the printer from the Optional Paper Drawers (Tray2, Tray 3) if they are installed.
CAUTION:
<2-41> The printer weighs approximately 28 kg (62 lb). Use two personsto carry the printer. Use appropriate lifting precautions.
hcsf
0241
e. Open the front cover and remove the toner cartridge.
f. Check for damage by manually rotating the Main Motorclockwise and watching the Gear Drive Asm.
Does the Gear Drive Asm function correctly?
Reinstall the Gear Drive Asm. Goto step 4.
Repair/replace the Gear DriveAsm.
4. Check the Toner Cartridge:
a. Replace the Toner Cartridge.
b. Enter Service Mode (see “Accessing Service Mode” onpage 280.)
c. Print a Service Page from Tray 1 to the Main Output Bin(see “Printing the Service Page” on page 295.)
Does error code 430 recur?
Go to step 5 on page 201. Replacing the Toner Cartridgefixed the problem. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 200
Table 44. Map 430: Motor Error (continued)
Step Questions/Actions Yes No
5. Check the Fuser Asm:
CAUTION:<2-43> High Temperature; switch off the printer and allowat least 30 minutes for parts in this area to cool beforehandling.1. Power off the printer.
2. Replace the Fuser Asm 120 v, Fuser Asm 230 v.
3. Power on the printer and print a Service Page from Tray 1to the Main Output Bin (see “Printing the Service Page” onpage 295.)
Does error code 430 recur?
Repair/replace the following, oneat a time. After eachreplacement, check to see if theproblem has been fixed.
v Feed Asm
v Paper Handling Asm
v Aux Tray
v Env Tray Asm (if installed)
v Option Paper Drawer (ifinstalled)
Replacing the Fuser Asm fixedthe problem. Verify the originalcustomer job prints correctly.
Chapter 1. Diagnosing Problems 201
MAP 451: Fan ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a problem with the Fan Motor. Fan Motor 75%
MCU PCB 10%
LVPS 120V, LVPS 230V 10%
Harness (J28 - J281) 5%
Table 45. Map 451: Fan Error
Step Questions/Actions Yes No
1. Check the Fan Motor:a. Power off the printer.b. Power on the printer.
Does the Fan Motor turn at any time?
Go to step 3 on page 203. Go to step 2.
2. Check the Fan Motor Harness:a. Power off the printer.b. Check the Fan Motor Harness J283 from the LVPS
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fan Motorv LVPS 120V, LVPS 230V
Replace the Fan Motor.
Chapter 1. Diagnosing Problems 202
Table 45. Map 451: Fan Error (continued)
Step Questions/Actions Yes No
3. Check the Harness (J28 - J281):1. Power off the printer.2. Check the Harness (J28 - J281) from the MCU PCB
to the LVPS to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed.v Fan Motorv MCU PCBv LVPS 120V, LVPS 230V
Repair/replace the Harness (J28- J281).
Chapter 1. Diagnosing Problems 203
MAP 454: Fuser ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a problem with the Fuser Asm. Fuser Asm 120 v, Fuser Asm 230 v 75%
MCU PCB 10%
LVPS 120V, LVPS 230V 10%
Harness (J27, J11, J262-J271) 4%
Harness (J28 - J281) 1%
Table 46. Map 454: Fuser Error
Step Questions/Actions Yes No
1. Replace the Fuser Asm 120 v, Fuser Asm 230 v:
CAUTION:<2-43> High Temperature; switch off the printer andallow at least 30 minutes for parts in this area tocool before handling.a. Power off the printer.b. Replace the Fuser Asm 120 v, Fuser Asm 230 v.c. Power on the printer.
Does error code 454 occur?
Go to step 2 on page 205. The problem is fixed. Verify theoriginal customer job printscorrectly.
Chapter 1. Diagnosing Problems 204
Table 46. Map 454: Fuser Error (continued)
Step Questions/Actions Yes No
2. Check the Harness (J27, J11, J262 - J271):a. Power off the printer.b. Check the Harness (J27, J11, J262 - J271) from the
MCU PCB to the LVPS and Fuser Connector tomake sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 3. Repair/replace the Harness(J27, J11, J262-J271)
3. Check the Harness (J28 - J281):1. Power off the printer.2. Check the Harness (J28 - J281) from the MCU PCB
to the LVPS to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and does it havecontinuity?
Repair/replace the following:v LVPS 120V, LVPS 230Vv MCU PCB
Repair/replace the Harness (J28- J281)
Chapter 1. Diagnosing Problems 205
MAP 460: Offset ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Offset Direction Solenoid in theOffset Asm failed.
Offset Direction Solenoid (Offset Asm) 85%
MCU PCB 10%
Harness (J35 - J351) 5%
Table 47. Map 460: Offset Error
Step Questions/Actions Yes No
1. Is an Offset Asm installed on this printer? Go to step 2. Replace the MCU PCB.
2. Check the Harness (J35 - J351):a. Power off the printer.b. Check the Harness (J35 - J351) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 3. Repair/replace the Harness (J35- J351).
3. Has the Offset Asm already been replaced oncebecause of this problem? If you are not sure, answerno.
Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCB
Chapter 1. Diagnosing Problems 206
MAP 511: Laser ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a problem with the ROS Asm (Laser). ROS Asm (Laser) 70%
MCU PCB 10%
Toner Cartridge Key Sensor 10%
LVPS 120V, LVPS 230V 5%
Harness (J21 - J211, J212, J213) 3%
Harness (J22 - J223) 2%
Table 48. Map 511: Laser Error
Step Questions/Actions Yes No
1. Check the ROS Asm (Laser):a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run diagnostic 1110 (see “Diagnostic Menu” on
page 284).c. Listen for the ROS Motor to start to rotate.d. If you are unable to run the diagnostic, go to step 2
on page 208.
Does the ROS Motor rotate while the diagnostic isrunning?
Go to step 3 on page 208. Go to step 2 on page 208.
Chapter 1. Diagnosing Problems 207
Table 48. Map 511: Laser Error (continued)
Step Questions/Actions Yes No
2. Check the ROS harnesses:a. Power off the printer.b. Remove the ROS Asm (Laser).c. Check the Harness (J21 - J211, 212, 213) and
Harness (J22 - J223) to make sure they aresecurely fastened to the ROS Asm (Laser):
d. Check the harnesses for any damage.
Are the harnesses free of damage and in goodcondition?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCB
Repair/replace the Harness:v Harness (J21 - J211, J212,
J213)v Harness (J22 - J223)
3. The problem could be a defective Toner Cartridge KeySensor.a. Power off the printer.b. Check the Harness (J25 - J251) from the MCU PCB
to the Toner Cartridge Key Sensor for any damage.
Is the harness free of damage and in goodcondition?
Go to step 3. Repair/replace the Harness (J25- J251)
4. Check the ROS harnesses:1. Power off the printer.2. Remove the ROS Asm (Laser).3. Check the Harness (J21 - J211, 212, 213) and
Harness (J22 - J223) to make sure they aresecurely fastened to the ROS Asm (Laser):
4. Check the harnesses for any damage.
Are the harnesses free of damage and in goodcondition?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv LVPS 120V, LVPS 230Vv Toner Cartridge Key Sensor
Repair/replace the Harness:v Harness (J21 - J211, J212,
J213)v Harness (J22 - J223)
Chapter 1. Diagnosing Problems 208
MAP 623: Data ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a data underrun or overrun on thecurrent page being processed. By pressing enter, the printeraborts the current page and starts processing the next page.
Controller PCB 50%
NIC 50%
Table 49. Map 623: Data Error
Step Questions/Actions Yes No
1. This error is most likely caused by the computersending data to the printer. Either evaluate thatcomputer by printing to other sources, change the driverused, or contact your next level of support.
Is the computer working and sending pagescorrectly?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv NIC
The problem lies within thecomputer sending data to theprinter.
Chapter 1. Diagnosing Problems 209
MAP 630: NVM ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected a problem with the NVRAM on theMCU.
MCU PCB 100%
Table 50. Map 630: NVM Error
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 630?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the NVRAM settings:1. Enter the Factory Adjustments Menu (see “Factory
Adjust Menu” on page 288).2. Check the parameters for each value in the Factory
Adjustments.3. If you can’t enter the Service Mode, replace the
MCU PCB.
Are all parameters set correctly? If unsure, set todefaults and retest.
Replace the MCU PCB. Enter the correct parameters. Ifthe problem recurs, replace theMCU PCB.
Chapter 1. Diagnosing Problems 210
MAP 631: NVRAM ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with the NVRAM on theController PCB.
Controller PCB 100%
Table 51. Map 631: NVRAM Error
Step Questions/Actions Yes No
1. Reset the printer.1. Power off the printer.2. Wait two minutes.3. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 631?
Replace the Controller PCB. The problem appears to beintermittent. If the problemrecurs, replace the ControllerPCB.
Chapter 1. Diagnosing Problems 211
MAP 650: Service ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Service Port failed. MCU PCB 95%
Service Cable 5%
Table 52. Map 650: Service Error
Step Questions/Actions Yes No
1. Are you attempting to use the Service Port inService Mode?
Go to step 2. The Service Port is onlydesigned for use in ServiceMode. Do not use this port forany other reason.
2. Check the Service Cable:a. Check the connections on the Service Cable.
Is the Service Cable in good condition and correctlyconnected?
Go to step 3. Repair/replace the ServiceCable.
3. There appears to be a hardware problem with theService Port. Do not replace the MCU PCB unlessother problems occur. Use the Operator Panel toaccess the Service Mode.
Chapter 1. Diagnosing Problems 212
MAP 651: Boot ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with the boot file on theCompact Flash.
Compact Flash 80%
Controller PCB 20%
Table 53. Map 651: Boot Error
Step Questions/Actions Yes No
1. Reset the printer.1. Power off the printer.2. Wait two minutes.3. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 651?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Compact Flashv Controller PCB
The problem appears to beintermittent. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Compact Flashv Controller PCB
Chapter 1. Diagnosing Problems 213
MAP 652: Memory ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with the Memory DIMM. Memory DIMM 80%
Controller PCB 20%
Table 54. Map 652: Memory Error
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 652?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Compact Flashv Controller PCB
The problem appears to beintermittent. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Compact Flashv Controller PCB
2. Check the Memory DIMM:
Is there more than one Memory DIMM installed inthis printer?
Go to step 3 on page 215. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Memory DIMMv Controller PCB.
Chapter 1. Diagnosing Problems 214
Table 54. Map 652: Memory Error (continued)
Step Questions/Actions Yes No
3. Check the Memory DIMMs:1. Power off the printer.2. Remove each Memory DIMM, one at a time, to see
if a single Memory DIMM is causing the problem.3. After each removal, power on the printer.
Is the problem caused by only one Memory DIMM?
Replace the failing MemoryDIMM
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCB.v Both Memory DIMMs.
Chapter 1. Diagnosing Problems 215
MAP 653: File ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with the file system onthe Compact Flash.
Compact Flash 80%
Controller PCB 20%
Table 55. Map 653: File Error
Step Questions/Actions Yes No
1. Reset the printer.1. Power off the printer.2. Wait two minutes.3. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 651?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Compact Flashv Controller PCB
The problem appears to beintermittent. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Compact Flashv Controller PCB
Chapter 1. Diagnosing Problems 216
MAP 654: HW Error (MCU)Symptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with MCU communication. MCU PCB 60%
Controller PCB 35%
LVPS 120V, LVPS 230V 4%
Harness (J28 - J281) 1%
Table 56. Map 654: HW Error (MCU)
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 654?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the connection:a. Power off the printer.b. Check the connection between the MCU PCB and
the Controller PCB. Reseat this connection.c. Power on the printer.
Do you still have an error code 654?
Go to step 3 on page 218. The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v MCU PCBv Controller PCB
Chapter 1. Diagnosing Problems 217
Table 56. Map 654: HW Error (MCU) (continued)
Step Questions/Actions Yes No
3. Check the Harness (J28 - J281):1. Power off the printer.2. Check the Harness (J28 - J281) from the MCU PCB
to the LVPS to make sure that it is correctlyconnected and not damaged.
3. Check for continuity between the following pins:v PJ28-10 to PJ281-10
Is the harness free of damage and does it havecontinuity?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv LVPS 120V, LVPS 230Vv Controller PCB
Repair/replace the Harness (J28- J281).
Chapter 1. Diagnosing Problems 218
MAP 661: Firmware ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with its code. Controller PCB 99%
Infoprint 21 code 1%
Table 57. Map 661: Firmware Error
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 661?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the code:a. Power off the printer.b. Install a new Compact Flash or download new code,
if possible.c. Power on the printer.
Do you still have an error code 661?
Go to step 3. The problem appears to beisolated to the original code. Ifthe problem recurs, go to step3.
3. Check the Controller PCB:1. Power off the printer.2. Install a new Controller PCB.3. Power on the printer.
Do you still have an error code 661?
Contact your next level ofsupport.
The problem appears to beisolated to the broken ControllerPCB. If the problem recurs,contact your next level ofsupport.
Chapter 1. Diagnosing Problems 219
MAP 671: Disk ErrorSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a problem with the Hard Drive Hard Drive 90%
Controller PCB 10%
Table 58. Map 671: Disk Error
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 671?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the connection:1. Power off the printer.2. Check the connection between the Hard Drive and
the Controller PCB. Reseat this connection.3. Power on the printer.
Do you still have an error code 671?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Hard Drivev Controller PCB
The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Hard Drivev Controller PCB
Chapter 1. Diagnosing Problems 220
MAP 699: HW Error (Offset)Symptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected that the Offset Circuitry failed. MCU PCB 85%
Offset Asm 10%
Harness (J35 - J351) 5%
Table 59. Map 699: HW Error (Offset)
Step Questions/Actions Yes No
1. Check the Harness (J35 - J351):a. Power off the printer.b. Check the Harness (J35 - J351) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 2. Repair/replace the Harness (J35- J351).
2. Is an Offset Asm installed on this printer? Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asm.v MCU PCB
Replace the MCU PCB.
Chapter 1. Diagnosing Problems 221
MAP 714: Duplex ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Duplex Asm failed. Duplex Asm 85%
MCU PCB 10%
Harness (J34 - J341) (see “Harness (J34-P341)” onpage 403)
5%
Table 60. Map 714: Duplex Error
Step Questions/Actions Yes No
1. Is a Duplex Asm installed on this printer? Go to step 2. Replace the MCU PCB.
2. Check the Harness (J34 - J341):a. Power off the printer.b. Check the Harness (J34 - J341) from the MCU PCB
to make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 3. Repair/replace the Harness (J34- J341).
3. Has the Duplex Asm already been replaced oncebecause of this problem? If you are unsure, answerno.
Replace the MCU PCB. Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Duplex Asmv MCU PCB
Chapter 1. Diagnosing Problems 222
MAP 772: ENV ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Env Tray Asm failed. Env Tray Asm 85%
MCU PCB 10%
Interface PCB 5%
Harness (J23 - J231) 3%
Env Connector - Female 2%
Table 61. Map 772: ENV Error
Step Questions/Actions Yes No
1. Is an Env Tray Asm installed on this printer? Go to step 2. Replace the MCU PCB.
2. Check the Harness (J23 - J231):a. Power off the printer.b. Check the Harness (J23 - J231) from the MCU PCB
to the Interface PCB to make sure that it is correctlyconnected and not damaged.
Is the harness free of damage and correctlyconnected?
Go to step 3 on page 224. Repair/replace the Harness (J23- J231).
Chapter 1. Diagnosing Problems 223
Table 61. Map 772: ENV Error (continued)
Step Questions/Actions Yes No
3. Check the Env Connector -Female:a. Power off the printer.b. Remove the Env Tray Asm.c. Check the Env Connector -Female to make sure
that it is correctly connected to the Interface PCBand not damaged.
Is the connector correctly connected and notdamaged?
Go to step 4. Repair/replace the EnvConnector - Female.
4. Has the Env Tray Asm already been replaced oncebecause of this problem? If unsure, answer no.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem has been fixed.v MCU PCBv Interface PCBv Env Connector - Female
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Env Tray Asmv MCU PCBv Interface PCBv Env Connector - Female
Chapter 1. Diagnosing Problems 224
MAP 795: Offset ErrorSymptom Explanation Suspected FRUs/Causes Probability
MCU Logic detected the Offset Direction Solenoid failed. Offset Asm 85%
MCU PCB 10%
Harness (J35 - J351) 5%
Table 62. Map 795: Offset Error
Step Questions/Actions Yes No
1. Is an Offset Asm installed on this printer? Go to step 2. Replace the MCU PCB.
2. Check the Harness (J35 - J351):a. Power off the printer.b. Remove the Offset Asm.c. Check the Harness (J35 - J351) from the MCU PCB
to the connector that the Offset Asm connects toand make sure that it is correctly connected and notdamaged.
Is the harness free of damage and correctlyconnected?
Go to step 3. Repair/replace the following:v MCU PCBv Harness (J35 - J351).
3. Has the Offset Asm already been replaced oncebecause of this problem? If unsure, answer no.
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v MCU PCBv Harness (J35 - J351).
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Offset Asmv MCU PCBv Harness (J35 - J351).
Chapter 1. Diagnosing Problems 225
MAP 821: PS OptionSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB detected a problem with the FontsCompact Flash.
Font Flash 70%
Controller PCB 30%
Table 63. Map 821: PS Option
Step Questions/Actions Yes No
1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.
Do you still have a 821 error?
Go to step 2. Problem solved.
2. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.
Do you still have the error?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Font Flashv Controller PCB
Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Font Flashv Controller PCB
Chapter 1. Diagnosing Problems 226
MAP 831: Controller Loop TrapSymptom Explanation Suspected FRUs/Causes Probability
Controller logic detected a portion of code was stuck in aloop. This error triggers after five minutes.
Options 80%
Controller PCB 19%
Infoprint 21 code 1%
Table 64. Map 831: Controller Loop Trap
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)d. Wait five minutes.
Do you still have an error code 831?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the options:a. Power off the printer.b. Remove the options, one at a time, including
Controller options. Power on after each removal,and wait five minutes to check to see if the optioncaused the problem.
Did removing one of the options stop the error code831?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Problem option.v Controller PCB.
If the problem recurs, go tostep 3.
Replace the Controller PCB. Ifthe problem recurs, go to step3.
3. The problem could be with the Infoprint 21 code. Contact your next level of support.
Chapter 1. Diagnosing Problems 227
MAP 851: IPDS OptionSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB detected a problem with the IBMAFP/IPDS Module.
IBM AFP/IPDS Module 70%
Controller PCB 30%
Table 65. Map 851: IPDS Option
Step Questions/Actions Yes No
1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.
Do you still have the error?
Go to step 2. Problem solved.
2. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.
Do you still have the error?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Chapter 1. Diagnosing Problems 228
MAP 852: IPDS Add MemSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB does not have enough memory toprocess the IPDS job.
Memory DIMM 40%
Controller PCB 30%
IBM AFP/IPDS Module 30%
Table 66. Map 852: IPDS Add Mem
Step Questions/Actions Yes No
1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.d. Print the customer job.
Do you still have the error?
Go to step 2. Problem solved.
2. Check the installed memory:a. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)b. Look at the ″Installed Memory″ on the printed
Service Page.
Does the memory listed match the memory installedin the Controller PCB?
Go to step 4 on page 230. Go to step 3 on page 230.
Chapter 1. Diagnosing Problems 229
Table 66. Map 852: IPDS Add Mem (continued)
Step Questions/Actions Yes No
3. Check the installed memory:a. Power off the printer.b. Remove all memory DIMMs.c. Check the memory DIMMs by putting one in the
printer.d. Power on the printer.e. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)f. Verify the amount of memory on the Service Page
matches the amount of memory in the printer.g. Repeat for all memory DIMMs.
Does the memory listed match the memory installedin the Controller PCB for all DIMMs?
Problem solved. Repair/replace the following,one at a time. After eachreplacement check to see if theproblem has been fixed.v Failing Memory DIMMv Controller PCB
4. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.
Do you still have the error?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Controller PCBv IBM AFP/IPDS Module
Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement check to seeif the problem has been fixed.v Controller PCBv IBM AFP/IPDS Module
Chapter 1. Diagnosing Problems 230
MAP 853: IPDS Low MemSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB detected a problem with the IBMAFP/IPDS Module.
IBM AFP/IPDS Module 70%
Controller PCB 30%
Table 67. Map 853: IPDS Low Mem
Step Questions/Actions Yes No
1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.
Do you still have an error code 853?
Go to step 2. This problem could beintermittent. If the problemrecurs, go to step 2.
2. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.
Do you still have an error code 853?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Chapter 1. Diagnosing Problems 231
MAP 854: IPDS ErrorSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB detected a problem with the IPDS Fonts. IBM AFP/IPDS Module 70%
Controller PCB 30%
Table 68. Map 854: IPDS Error
Step Questions/Actions Yes No
1. Verify the Error:a. Power off the printer.b. Wait 20 seconds.c. Power on the printer.
Do you still have an error code 854?
Go to step 2. This problem could beintermittent. If the problemrecurs, go to step 2.
2. Perform a cold reset.1. Power off the printer.2. While pressing the Online key, power on the printer.
Do you still have an error code 854?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Problem solved. If the errorrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v IBM AFP/IPDS Modulev Controller PCB
Chapter 1. Diagnosing Problems 232
MAP 860: No CX Host SyncSymptom Explanation Suspected FRUs/Causes Probability
The Coax NIC detected a problem between itself and thehost computer.
Coax NIC 50%
Host Computer 50%
Table 69. Map 860: No CX Host Sync
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 860?
Replace the Coax NIC. If theproblem recurs, go to step 2.
The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. The problem seems to be with the Host Computer. Verify correct host computer operation or call your next level of support.
Chapter 1. Diagnosing Problems 233
MAP 861: No TX Host SyncSymptom Explanation Suspected FRUs/Causes Probability
The Twinax NIC detected a problem between itself and thehost computer.
Twinax NIC 50%
Host Computer 50%
Table 70. Map 861: No TX Host Sync
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 861?
Replace the Twinax NIC. If theproblem recurs, go to step 2.
The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. The problem seems to be with the Host Computer. Verify correct host computer operation or call your next level of support.
Chapter 1. Diagnosing Problems 234
MAP 862: CX Key RequestSymptom Explanation Suspected FRUs/Causes Probability
The Coax NIC detected a missing key between itself and thehost computer.
Coax NIC 50%
Host Computer 50%
Table 71. Map 862: CX Key Request
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 862?
Replace the Coax NIC. If theproblem recurs, go to step 2.
The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. The problem seems to be with the host computer. Verify correct host computer operation or call your next level of support.
Chapter 1. Diagnosing Problems 235
MAP 872: Network OptionSymptom Explanation Suspected FRUs/Causes Probability
The Controller PCB detected a problem between itself andthe Coax or Twinax NIC Card.
Coax NIC 50%
Controller PCB 50%
Table 72. Map 872: Network Option
Step Questions/Actions Yes No
1. Reset the printer.a. Power off the printer.b. Wait two minutes.c. Enter Service Mode (see “Accessing Service Mode”
on page 280.)
Do you still have an error code 872?
Go to step 2. The problem appears to beintermittent. If the problemrecurs, go to step 2.
2. Check the connection:1. Power off the printer.2. Check the connection between the NIC and the
Controller PCB. Reseat this connection.3. Power on the printer.
Do you still have an error code 872?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v NIC Cardv Controller PCB
The problem appears to be aloose connection. If the problemrecurs, repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v NIC Cardv Controller PCB
Chapter 1. Diagnosing Problems 236
MAP 900: Background or Dark ImageSymptom Explanation Suspected FRUs/Causes Probability
There is toner contamination on all or part of the page. Thecontamination can vary from a very light gray dusting to avery dark print.
Toner Cartridge 80%
HVPS 10%
BTR Support Asm 4%
Bias Transfer Roll 1%
Fuser Asm 120 v, Fuser Asm 230 v 1%
Harness (J26 - J261) 1%
MCU PCB 1%
Controller PCB 1%
ROS Asm (Laser) 1%
Table 73. Map 900: Background or Dark Image
Step Questions/Actions Yes No
1. Check the density setting:a. Check the density setting in the Config Menu to
ensure that it is set at the default value of 3.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is there still background on the print?
Go to step 2 on page 238. The problem could beintermittent. Verify that theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 237
Table 73. Map 900: Background or Dark Image (continued)
Step Questions/Actions Yes No
2. Check the printer:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1010 (see “Diagnostic Menu” on
page 284).
Is there background on this print?
Go to step 3. The problem is not with theprinter. Repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Controller PCBv MCU PCB
3. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is there still background on the print?
Go to step 4. Problem solved. Verify theoriginal job prints correctly.
4. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Go to step 5. Reform, clean, or replace thecontacts on the BTR SupportAsm.
5. Check the Bias Transfer Roll:a. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 6 on page 239. Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 238
Table 73. Map 900: Background or Dark Image (continued)
Step Questions/Actions Yes No
6. Check the Harness (J26 - J261):a. Power off the printer.b. Check the harness from the MCU PCB to the
HVPS.
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261) as necessary.
Go to step 7.
7. Repair/replace the following, one at a time. After eachreplacement, determine if the problem is fixed byprinting a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm 230 v
CAUTION:<2-43> High Temperature; switch off the printerand allow at least 30 minutes for parts in thisarea to cool before handling.
v HVPSv MCU PCBv ROS Asm (Laser)
Chapter 1. Diagnosing Problems 239
MAP 905: All Black PrintSymptom Explanation Suspected FRUs/Causes Probability
The entire printed page is black. Toner Cartridge 50%
HVPS 40%
BTR Support Asm 5%
ROS Asm (Laser) 2%
Harness (J26 - J261) 1%
MCU PCB 1%
Controller PCB 1%
Table 74. Map 905: All Black Print
Step Questions/Actions Yes No
1. Check the printer:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1010 (see “Diagnostic Menu” on
page 284).
Is the print completely black?
Go to step 2. The problem is not with theprinter. Repair/replace thefollowing, one at a time. Aftereach replacement, check to seeif the problem has been fixed.v Controller PCBv MCU PCB
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still completely black?
Go to step 3 on page 241. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 240
Table 74. Map 905: All Black Print (continued)
Step Questions/Actions Yes No
3. Check the ROS Asm:a. Power off the printer.b. Remove the ROS Asm (Laser).c. Use a sheet of paper to cover the laser window on
the ROS Asm.d. Reinstall the ROS Asm (Laser).e. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still completely black?
Go to step 4. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB
4. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Go to step 5. Reform, clean, or replace thecontacts on the BTR SupportAsm.
5. Check the Harness (J26 - J261):1. Power off the printer.2. Check the harness from the MCU PCB to the
HVPS.3. Test for continuity between:v PJ26-14 and PJ261-14
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261) as necessary.
Replace the HVPS.
Chapter 1. Diagnosing Problems 241
MAP 910: All Blank PrintSymptom Explanation Suspected FRUs/Causes Probability
The entire printed page is blank. Toner Cartridge 70%
HVPS 20%
BTR Support Asm 3%
Bias Transfer Roll 2%
Harness (J26 - J261) 1%
LVPS 120V, LVPS 230V 1%
MCU PCB 1%
Controller PCB 1%
ROS Asm (Laser) 1%
Harness (J22 - J223) 1%
Table 75. Map 910: All Blank Print
Step Questions/Actions Yes No
1. Check the density setting:a. Check the DENSITY item in the Config Menu to
ensure that it is set at the default value of 3.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still completely blank?
Go to step 2 on page 243. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 242
Table 75. Map 910: All Blank Print (continued)
Step Questions/Actions Yes No
2. Check the printer:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1010 (see “Diagnostic Menu” on
page 284).Note: This diagnostic produces a test print thatdoes not use the Controller PCB.
Is the print still completely blank?
Go to step 3. Go to step 8 on page 244.
3. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still completely blank?
Go to step 4. Problem solved. Verify theoriginal job prints correctly.
4. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm
and ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Go to step 5. Reform, clean, or replace thecontacts on the BTR SupportAsm.
5. Check the ROS Asm:a. Remove the ROS Asm (Laser).b. Check the laser window for contamination that could
be blocking the laser beam.
Is the laser window clean?
Go to step 6 on page 244. Clean the laser window orreplace the ROS Asm (Laser).
Chapter 1. Diagnosing Problems 243
Table 75. Map 910: All Blank Print (continued)
Step Questions/Actions Yes No
6. Check the Bias Transfer Roll:a. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 7. Clean or replace the BiasTransfer Roll.
7. Check the Harness (J26 - J261):a. Power off the printer.b. Check the harness from the MCU PCB to the
HVPS.
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261).
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv LVPS 120V, LVPS 230Vv ROS Asm (Laser)v MCU PCBv Controller PCB
8. Check the Harness (J22 - J223):1. Power off the printer.2. Check the harness from the MCU PCB to the ROS
Asm (Laser).
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J22- J223).
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Controller PCBv MCU PCB
Chapter 1. Diagnosing Problems 244
MAP 920: Damaged PageSymptom Explanation Suspected FRUs/Causes Probability
The page is bent, wrinkled, creased or torn. Toner Cartridge 50%
Fuser Asm 120 v, Fuser Asm 230 v 30%
Bias Transfer Roll 6%
550-Sheet Tray Asm 5%
Paper Handling Asm 5%
Feed Asm 2%
Exit Asm 2%
Table 76. Map 920: Damaged Page
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray.d. Determine which trays are damaging paper.
Is the print still damaged?
Go to step 2. The problem might be with thecustomer job. Verify the originaljob prints correctly.
2. Are all trays damaging paper? Go to step 6 on page 247. Go to step 3 on page 246.
Chapter 1. Diagnosing Problems 245
Table 76. Map 920: Damaged Page (continued)
Step Questions/Actions Yes No
3. Check the paper path for the tray with the problem:a. Check the paper path in the tray for fragments of
paper. Replace any worn, contaminated, or brokenparts.
b. Print a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)
Is the print still damaged?
Go to step 4. Problem solved. Verify theoriginal job prints correctly.
4. Check the paper path:a. Check the paper path in all location areas for
fragments of paper. Replace any worn,contaminated, or broken parts.
b. Print a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)
Is the print still skewed?
Go to step 5. Problem solved. Verify theoriginal job prints correctly.
5. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still damaged?
Go to step 6 on page 247. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 246
Table 76. Map 920: Damaged Page (continued)
Step Questions/Actions Yes No
6. Check the Bias Transfer Roll:1. Power off the printer.2. Remove the Bias Transfer Roll3. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Repair/replace the following,one at a time. After eachreplacement, check to see if theproblem has been fixed.v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v Feed Asmv 550-Sheet Tray Asmv Paper Handling Asmv Exit Asm
Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 247
MAP 930: Not Fused or Partially Fused ImageSymptom Explanation Suspected FRUs/Causes Probability
The image on the printed page is not completely fused (thetoner easily rubs off). If the print also has light density, correctthis first (see “MAP 935: Light Image” on page 250).
Fuser Asm 120 v, Fuser Asm 230 v 70%
MCU PCB 20%
LVPS 120V, LVPS 230V 10%
Table 77. Map 930: Not Fused or Partially Fused Image
Step Questions/Actions Yes No
1. Check the paper:a. Ask the customer about the type of paper and input
tray that is having the fusing problem.b. Load fresh, dry paper of the type that has been
failing in the tray the customer was using.c. Print a Service Page from that tray (see “Printing
the Service Page” on page 295.)d. Check the fusing quality on the print.
Is the image fused correctly?
The problem is with the papersupply or customer job. If theoriginal job does not printcorrectly, go to step 2 onpage 249.
Go to step 2 on page 249.
Chapter 1. Diagnosing Problems 248
Table 77. Map 930: Not Fused or Partially Fused Image (continued)
Step Questions/Actions Yes No
2. Check the Media Type:1. Check the Tray Type setting in the Paper Menu in
the Operator Panel for the tray with the problem toensure that it is correct.
Is the setting of Media Type correct?
Set the Media Type to thecorrect setting.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v MCU PCBv LVPS 120V, LVPS 230V
Chapter 1. Diagnosing Problems 249
MAP 935: Light ImageSymptom Explanation Suspected FRUs/Causes Probability
The image is light. Toner Cartridge 70%
Bias Transfer Roll 20%
HVPS 4%
BTR Support Asm 1%
Fuser Asm 120 v, Fuser Asm 230 v 1%
MCU PCB 1%
ROS Asm (Laser) 1%
Harness (J26 - J261) 1%
LVPS 120V, LVPS 230V 1%
Table 78. Map 935: Light Image
Step Questions/Actions Yes No
1. Check the density setting:a. Check the density setting in the Config Menu to
ensure that it is set at the default value of 3.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still light?
Go to step 2 on page 251. The problem could beintermittent. Verify that theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 250
Table 78. Map 935: Light Image (continued)
Step Questions/Actions Yes No
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still light?
Go to step 3. Problem solved. Verify theoriginal job prints correctly.
3. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Go to step 4. Reform, clean, or replace thecontacts on the BTR SupportAsm.
4. Check the Bias Transfer Roll:a. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 5. Clean or replace the BiasTransfer Roll.
5. Check the ROS Asm:a. Remove the ROS Asm (Laser).b. Check the laser window for contamination that could
be blocking the laser beam.
Is the laser window clean?
Go to step 6 on page 252. Clean the laser window orreplace the ROS Asm.
Chapter 1. Diagnosing Problems 251
Table 78. Map 935: Light Image (continued)
Step Questions/Actions Yes No
6. Check the Harness (J26 - J261):1. Power off the printer.2. Check the harness from the MCU PCB to the
HVPS.
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261) as necessary.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv BTR Support Asmv Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v MCU PCBv ROS Asm (Laser)v LVPS 120V, LVPS 230Vv Controller PCBv Feed Asm
Chapter 1. Diagnosing Problems 252
MAP 940: Image RegistrationSymptom Explanation Suspected FRUs/Causes Probability
The image is not correctly positioned on the page. If theimage is not parallel with the edges of the page, see “MAP950: Skewed Image” on page 260).
Toner Cartridge 30%
Registration Clutch - Electric 30%
Paper Handling Asm 20%
Feed Asm 10%
550-Sheet Tray Asm 8%
MCU PCB 1%
Controller PCB 1%
ROS Asm (Laser) 1%
Table 79. Map 940: Image Registration
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray. (see “Printing the Service Page” onpage 295.)
d. Determine which trays are having a registrationproblem.
Is the print registration still bad?
Go to step 2 on page 254. The problem might be with thecustomer job. Verify the originaljob prints correctly.
Chapter 1. Diagnosing Problems 253
Table 79. Map 940: Image Registration (continued)
Step Questions/Actions Yes No
2. Are all trays having the registration problem? Go to step 6 on page 255. Go to step 3.
3. Check the registration settings:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Change all registration settings to their defaults. See
“Factory Adjust Menu” on page 288.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still misregistered?
Go to step 4. Problem solved. Verify theoriginal job prints correctly.
4. Check the Feed Asm for the tray with the registrationproblem:a. Power off the printer.b. Inspect the Feed Asm for damaged parts.
Is the Feed Asm damaged?
Replace the Feed Asm. Go to step 5.
5. Check the 550-Sheet Tray Asm for the tray with theregistration problem:a. Inspect the 550-Sheet Tray Asm for damaged parts.
Is the 550-Sheet Tray Asm damaged?
Replace the 550-Sheet TrayAsm.
Go to step 6 on page 255.
Chapter 1. Diagnosing Problems 254
Table 79. Map 940: Image Registration (continued)
Step Questions/Actions Yes No
6. Check the Registration Clutch - Electric:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Run Diagnostic 1280 (see “Diagnostic Menu” on
page 284).c. Listen for a click from the registration clutch when
the diagnostic is run, and a second clickapproximately one half second later.
Does the Registration Clutch - Electric clickcorrectly when the diagnostic is run?
Go to step 7. Replace the Registration Clutch- Electric.
7. Check the Paper Handling Asm:a. Power off the printer.b. Inspect the Paper Handling Asm for damaged parts,
especially the registration rollers.
Is the Paper Handling Asm damaged?
Replace the Paper HandlingAsm.
Go to step 8.
8. Replace the Toner Cartridge:1. Replace the Toner Cartridge.2. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still misregistered?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB
Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 255
MAP 941: Repeating Spots or VoidsSymptom Explanation Suspected FRUs/Causes Probability
There are spots or voids on the page that repeat at regularintervals.
Toner Cartridge 80%
Bias Transfer Roll 10%
Fuser Asm 120 v, Fuser Asm 230 v 5%
ROS Asm (Laser) 3%
MCU PCB 1%
Controller PCB 1%
Table 80. Map 941: Repeating Spots or Voids
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray.
Does the print still have spots or voids?
Go to step 2. The problem might be with thecustomer job. Verify the originaljob prints correctly.
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have spots or voids?
Go to step 3 on page 257. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 256
Table 80. Map 941: Repeating Spots or Voids (continued)
Step Questions/Actions Yes No
3. Check the Bias Transfer Roll:a. Power off the printer.b. Remove the Bias Transfer Roll and inspect it for
damage and contamination.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 4. Replace the Bias Transfer Roll.
4. Check the ROS Asm (Laser):1. Power off the printer.2. Remove the ROS Asm (Laser).3. Inspect the laser window for contamination or
anything else that would block the laser path.4. Reinstall the ROS Asm (Laser).5. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have spots or voids?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v ROS Asm (Laser)v MCU PCBv Controller PCB
Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 257
MAP 945: Residual or Ghost ImagesSymptom Explanation Suspected FRUs/Causes Probability
The printed page contains random light ghost images. Theimages may either be from a previous page or the currentpage.
Toner Cartridge 70%
Bias Transfer Roll 20%
Fuser Asm 120 v, Fuser Asm 230 v 10%
Table 81. Map 945: Residual or Ghost Images
Step Questions/Actions Yes No
1. Check the paper supply:a. Replace the paper with fresh, dry standard paper.b. Print the problem image or a Service Page from
Tray 1 to the Main Bin (see “Printing the ServicePage” on page 295.)
Does the print still contain ghost images?
Go to step 2. Problem solved. Verify theoriginal job prints correctly.
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still contain ghost images?
Go to step 3 on page 259. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 258
Table 81. Map 945: Residual or Ghost Images (continued)
Step Questions/Actions Yes No
3. Check the Bias Transfer Roll:1. Power off the printer.2. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Replace the Fuser Asm 120 v,Fuser Asm 230 v.
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutes forparts in this area to coolbefore handling.
Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 259
MAP 950: Skewed ImageSymptom Explanation Suspected FRUs/Causes Probability
The image on the printed page is not parallel with the edgesof the page. If the image is not positioned correctly on thepage, see “MAP 940: Image Registration” on page 253).
Toner Cartridge 30%
Paper Handling Asm 30%
Feed Asm 20%
550-Sheet Tray Asm 17%
MCU PCB 1%
Controller PCB 1%
ROS Asm (Laser) 1%
Table 82. Map 950: Skewed Image
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray (see “Printing the Service Page” onpage 295.)
d. Determine which trays are having a registrationproblem.
Is the print still skewed?
Go to step 2. The problem might be with thecustomer job. Verify the originaljob prints correctly.
2. Are all trays having the skew problem? Go to step 6 on page 261. Go to step 3 on page 261.
Chapter 1. Diagnosing Problems 260
Table 82. Map 950: Skewed Image (continued)
Step Questions/Actions Yes No
3. Check the paper path for the tray with the skewproblem:a. Check the paper path in the tray for fragments of
paper. Replace any worn, contaminated, or brokenparts.
b. Print a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)
Is the print still skewed?
Go to step 4. Problem solved. Verify theoriginal job prints correctly.
4. Check the Feed Asm for the tray with the skewproblem:a. Power off the printer.b. Inspect the Feed Asm for damaged parts. Install
new Feed, Pick, and Retard rollers if they are worn.
Is the Feed Asm damaged?
Replace the Feed Asm. Go to step 5.
5. Check the 550-Sheet Tray Asm for the tray with theskew problem:a. Inspect the 550-Sheet Tray Asm for damaged parts.
Is the 550-Sheet Tray Asm damaged?
Replace the 550-Sheet TrayAsm.
Go to step 6.
6. Check the paper path:a. Check the paper path in all location areas for
fragments of paper. Replace any worn,contaminated, or broken parts.
b. Print a Service Page from Tray 1 to the Main OutputBin (see “Printing the Service Page” on page 295.)
Is the print still skewed?
Go to step 7 on page 262. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 261
Table 82. Map 950: Skewed Image (continued)
Step Questions/Actions Yes No
7. Check the Paper Handling Asm:a. Power off the printer.b. Inspect the Paper Handling Asm for damaged parts,
especially the registration rollers.
Is the Paper Handling Asm damaged?
Replace the Paper HandlingAsm.
Go to step 8.
8. Replace the Toner Cartridge:1. Replace the Toner Cartridge.2. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Is the print still skewed?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB
Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 262
MAP 955: Spots on PrintsSymptom Explanation Suspected FRUs/Causes Probability
There are spots of toner randomly scattered on the print sideof the page.
Toner Cartridge 80%
Bias Transfer Roll 10%
Fuser Asm 120 v, Fuser Asm 230 v 6%
BTR Support Asm 1%
ROS Asm (Laser) 1%
MCU PCB 1%
Controller PCB 1%
Table 83. Map 955: Spots on Prints
Step Questions/Actions Yes No
1. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Are there still spots on the print?
Go to step 2. Problem solved. Verify theoriginal job prints correctly.
2. Check the Bias Transfer Roll:a. Power off the printer.b. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 3 on page 264. Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 263
Table 83. Map 955: Spots on Prints (continued)
Step Questions/Actions Yes No
3. Check the Toner Cartridge contacts:1. Remove the Toner Cartridge.2. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v ROS Asm (Laser)v MCU PCBv LVPS 120V, LVPS 230V
Reform, clean, or replace thecontacts on the BTR SupportAsm.
Chapter 1. Diagnosing Problems 264
MAP 965: Horizontal StreaksSymptom Explanation Suspected FRUs/Causes Probability
There are black lines running horizontally across the page. Toner Cartridge 50%
Bias Transfer Roll 20%
HVPS 20%
Fuser Asm 120 v, Fuser Asm 230 v 6%
BTR Support Asm 1%
ROS Asm (Laser) 1%
MCU PCB 1%
Controller PCB 1%
Table 84. Map 965: Horizontal Streaks
Step Questions/Actions Yes No
1. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Are there still lines on the page?
Go to step 2 on page 266. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 265
Table 84. Map 965: Horizontal Streaks (continued)
Step Questions/Actions Yes No
2. Check the ROS Asm:a. Power off the printer.b. Use a sheet of paper to cover the laser window on
the toner cartridge.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Are there still lines on the page?
Go to step 3. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v ROS Asm (Laser)v MCU PCBv Controller PCB
3. Check the Bias Transfer Roll:a. Power off the printer.b. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 4 on page 267. Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 266
Table 84. Map 965: Horizontal Streaks (continued)
Step Questions/Actions Yes No
4. Check the Toner Cartridge contacts:1. Remove the Toner Cartridge.2. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
Reform, clean, or replace thecontacts on the BTR SupportAsm.
Chapter 1. Diagnosing Problems 267
MAP 970: Vertical StreaksSymptom Explanation Suspected FRUs/Causes Probability
There are black lines running vertically along the page. Toner Cartridge 50%
Bias Transfer Roll 40%
Fuser Asm 120 v, Fuser Asm 230 v 6%
HVPS 2%
MCU PCB 1%
Controller PCB 1%
Table 85. Map 970: Vertical Streaks
Step Questions/Actions Yes No
1. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Are there still lines on the page?
Go to step 2. Problem solved. Verify theoriginal job prints correctly.
2. Check the ROS Asm:a. Power off the printer.b. Use a sheet of paper to cover the laser window on
the toner cartridge.c. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Are there still lines on the page?
Go to step 3 on page 269. Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v MCU PCBv Controller PCB
Chapter 1. Diagnosing Problems 268
Table 85. Map 970: Vertical Streaks (continued)
Step Questions/Actions Yes No
3. Check the Bias Transfer Roll:1. Power off the printer.2. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v HVPS
Clean or replace the BiasTransfer Roll.
Chapter 1. Diagnosing Problems 269
MAP 975: Voids on PrintsSymptom Explanation Suspected FRUs/Causes Probability
There are small areas of the image on the printed page thatare extremely light or missing completely.
Toner Cartridge 50%
Bias Transfer Roll 40%
Fuser Asm 120 v, Fuser Asm 230 v 5%
Harness (J26 - J261) 1%
HVPS 1%
ROS Asm (Laser) 1%
MCU PCB 1%
Controller PCB 1%
Table 86. Map 975: Voids on Prints
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray.
Does the print still have voids?
Go to step 2 on page 271. The problem might be with thecustomer job. Verify the originaljob prints correctly.
Chapter 1. Diagnosing Problems 270
Table 86. Map 975: Voids on Prints (continued)
Step Questions/Actions Yes No
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have voids?
Go to step 3. Problem solved. Verify theoriginal job prints correctly.
3. Check the Bias Transfer Roll:a. Power off the printer.b. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 4. Clean or replace the BiasTransfer Roll.
4. Check the Fuser Asm:
Do the voids occur regularly at intervals around61mm (2.4 in)?
Replace the Fuser Asm 120 v,Fuser Asm 230 v.
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutes forparts in this area to coolbefore handling.
Go to step 5 on page 272.
Chapter 1. Diagnosing Problems 271
Table 86. Map 975: Voids on Prints (continued)
Step Questions/Actions Yes No
5. Check the Harness (J26 - J261):1. Power off the printer.2. Check the harness from the MCU PCB to the
HVPS.3. Test for continuity between:v PJ26-5 and PJ261-5v PJ26-9 and PJ261-9v PJ26-12 and PJ261-12
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261) as necessary.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv ROS Asm (Laser)v MCU PCBv Controller PCB
Chapter 1. Diagnosing Problems 272
MAP 980: Horizontal VoidsSymptom Explanation Suspected FRUs/Causes Probability
There are horizontal bands on the printed page that areextremely light or missing entirely.
Toner Cartridge 50%
Bias Transfer Roll 30%
Gear Drive Asm 10%
Fuser Asm 120 v, Fuser Asm 230 v 4%
BTR Support Asm 1%
Harness (J26 - J261) 1%
HVPS 1%
ROS Asm (Laser) 1%
MCU PCB 1%
Controller PCB 1%
Table 87. Map 980: Horizontal Voids
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray.
Does the print still have voids?
Go to step 2 on page 274. The problem might be with thecustomer job. Verify the originaljob prints correctly.
Chapter 1. Diagnosing Problems 273
Table 87. Map 980: Horizontal Voids (continued)
Step Questions/Actions Yes No
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have voids?
Go to step 3. Problem solved. Verify theoriginal job prints correctly.
3. Check the Toner Cartridge contacts:a. Power off the printer.b. Remove the Toner Cartridge.c. Inspect the metal contacts on the BTR Support Asm
to ensure good contact with the Toner Cartridge.
Are the metal contacts intact and not deformed orcontaminated?
Go to step 4. Reform, clean, or replace thecontacts on the BTR SupportAsm.
4. Check the Bias Transfer Roll:a. Inspect the Bias Transfer Roll.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 5. Clean or replace the BiasTransfer Roll.
5. Check the Gear Drive Asm:a. Enter Service Mode (see “Accessing Service Mode”
on page 280.)b. Remove the Toner Cartridge.c. Run Diagnostic 1100 (see “Diagnostic Menu” on
page 284).d. Check the gear that meshes with the Toner
Cartridge.
Is the gear turning correctly?
Go to step 6 on page 275. Repair/replace the Gear DriveAsm.
Chapter 1. Diagnosing Problems 274
Table 87. Map 980: Horizontal Voids (continued)
Step Questions/Actions Yes No
6. Check the Fuser Asm:
Do the horizontal voids occur regularly at intervalsaround 61mm (2.4 in)?
Replace the Fuser Asm 120 v,Fuser Asm 230 v.
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutes forparts in this area to coolbefore handling.
Go to step 7.
7. Check the Harness (J26 - J261):1. Power off the printer.2. Check the harness from the MCU PCB to the
HVPS.3. Test for continuity between:v PJ26-11 and PJ261-11
Is the harness loose, damaged or disconnected?
Repair/replace the Harness (J26- J261) as necessary.
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v HVPSv ROS Asm (Laser)v MCU PCBv Controller PCB
Chapter 1. Diagnosing Problems 275
MAP 985: Vertical Band VoidsSymptom Explanation Suspected FRUs/Causes Probability
There are vertical bands on the printed page that areextremely light or missing entirely.
Toner Cartridge 50%
ROS Asm (Laser) 30%
Bias Transfer Roll 10%
Fuser Asm 120 v, Fuser Asm 230 v 8%
MCU PCB 1%
Controller PCB 1%
Table 88. Map 985: Vertical Band Voids
Step Questions/Actions Yes No
1. Check the paper supply:a. Check each tray and verify that the paper guides
are adjusted correctly to match the paper size in thetray.
b. Load fresh, dry paper in all trays.c. Print a Service Page from each tray including the
Aux Tray.
Does the print still have vertical band voids?
Go to step 2. The problem might be with thecustomer job. Verify the originaljob prints correctly.
2. Replace the Toner Cartridge:a. Replace the Toner Cartridge.b. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have vertical band voids?
Go to step 3 on page 277. Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 276
Table 88. Map 985: Vertical Band Voids (continued)
Step Questions/Actions Yes No
3. Check the Bias Transfer Roll:a. Power off the printer.b. Remove the Bias Transfer Roll and inspect it for
damage and contamination.
Is the Bias Transfer Roll intact and notcontaminated?
Go to step 4. Replace the Bias Transfer Roll.
4. Check the ROS Asm:1. Power off the printer.2. Remove the ROS Asm (Laser).3. Inspect the laser window for contamination or
anything else that would block the laser path.4. Reinstall the ROS Asm.5. Print a Service Page from Tray 1 to the Main Output
Bin (see “Printing the Service Page” on page 295.)
Does the print still have vertical band voids?
Repair/replace the following,one at a time. After eachreplacement, determine if theproblem is fixed by printing aService Page from Tray 1 to theMain Output Bin (see “Printingthe Service Page” on page 295.)v Fuser Asm 120 v, Fuser Asm
230 v
CAUTION:<2-43> High Temperature;switch off the printer andallow at least 30 minutesfor parts in this area to coolbefore handling.
v ROS Asm (Laser)v MCU PCBv Controller PCB
Problem solved. Verify theoriginal job prints correctly.
Chapter 1. Diagnosing Problems 277
Chapter 2. Diagnostic Tools
Printer Power-On Sequence Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Accessing Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280Accessing Service Mode from the CE Laptop PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281Accessing Service Mode from the Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
Service Mode Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Diagnostic Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284Diagnostic Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286Factory Adjust Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288Factory Adjustment Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289Test Print Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291Test Print Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294Printing the Service Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
Printing the Service Page from the CE Laptop PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295Printing the Service Page from the Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
This chapter contains detailed procedures such as printing test pages, printing a configuration page, working withthe error log, and performing checks and test necessary to support diagnostics.
© Copyright IBM Corp. 2000 278
Printer Power-On Sequence CheckThe following sequence of events should occur when printer power is switched on (no network card installed, andno error codes):Table 89. Power-On Sequence
Time after power on Duration Event
0 seconds 5 seconds Motors activate
12 seconds Black rectangles display on the top line of the operatorpanel
Until powered off Fan activates
12 seconds Approximately 48 seconds INFOPRINT 21 INITIALIZING displays on operator panel
2 seconds All LEDs light on operator panel
55 seconds Approximately 10 seconds INITIALIZING PLEASE WAIT displays on operator panel
65 seconds 1 second ONLINE IN PROGRESS displays on operator panel
66 seconds Until other activity READY displays on operator panel
Note: If a network interface card (NIC) is installed, the timings will change and the printer might take up to fiveminutes to initialize.
Chapter 2. Diagnostic Tools 279
Service ModeService Mode allows you to run diagnostic routines, execute test prints, and change factory adjustments.
Accessing Service ModeThere are two ways to access the Service Mode for the Infoprint 21:v “Accessing Service Mode from the CE Laptop PC” on page 281v “Accessing Service Mode from the Operator Panel” on page 283
Chapter 2. Diagnostic Tools 280
Accessing Service Mode from the CE Laptop PCTo enter Service Mode using a CE laptop PC attached to the Infoprint 21 serial Service Port perform the followingsteps:
Note: To set up a CE laptop PC to access service mode for the first time, click here:
Set up CE laptop PC
1. Power off the printer.2. Connect the CE laptop PC serial port to the Infoprint 21 serial Service Port using the serial cable contained in
kit P/N 62H4857.3. While pressing down both the Menu ↓ and Item ↓ keys, power on the printer.
Note: Continue holding down the keys until the message REQUEST RECEIVED is displayed on the operatorpanel.
4. The following messages display:INFOPRINT 21INITIALIZING
INFOPRINT 21REQUEST RECEIVED
DIAGNOSTIC MODEPLEASE WAIT
5. When initialization completes, the following message displays on the operator panel:DIAG MENUTEST = 1.0<0.0.
6. Power on the CE laptop PC.7. Start the Service PPP connection to the printer using a URL address of
http://10.0.0.2/ras/ras.htm
Chapter 2. Diagnostic Tools 281
Note: The operator panel keys are disabled when the Service PPP connection is active.8. To exit Service Mode when using the CE laptop PC:
a. Close all applications on the CE laptop PCb. Power off the CE laptop PCc. Power off the printerd. Disconnect the cable from the CE laptop PC to the printere. Power on the printer
Chapter 2. Diagnostic Tools 282
Accessing Service Mode from the Operator PanelTo enter Service Mode using the operator panel on the Infoprint 21 perform the following steps:1. Power off the printer.2. While pressing down both the Menu ↓ and Item ↓ keys, power on the printer.
Note: Continue holding down the keys until the message REQUEST RECEIVED is displayed on the operatorpanel.
3. The following messages display:INFOPRINT 21INITIALIZING
INFOPRINT 21REQUEST RECEIVED
DIAGNOSTIC MODEPLEASE WAIT
4. When initialization is complete, the following message displays on the operator panel:DIAG MENUTEST = 1.0<0.0.
5. Use the operator panel keys to navigate within the Service menus.6. To exit Service Mode when using the operator panel, power off and then power on the printer.
Chapter 2. Diagnostic Tools 283
Service Mode FunctionsThe following functions are provided as menus in Service Mode when using either the CE laptop PC using theserial Service Port or the Infoprint 21 operator panel:v Diagnostic Menuv Factory Adjustment Menuv Test Print Menu
In addition, an Error Log Menu is provided in Service Mode for the CE laptop PC using the serial Service Port.
Diagnostic MenuThe Diagnostic Menu allows you to run diagnostic routines such as checking sensors/switches, running motorsand fans, and picking solenoids and clutches. The following sections describe how to run diagnostics using eithera CE laptop PC attached to Infoprint 21 serial Service Port or the Infoprint 21 operator panel.
Note: In this book, diagnostic numbers are specified as 1xxx; on the operator panel diagnostic numbers aredisplayed as 1.x.x.x.
Using the Diagnostic Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Diagnostic Menu link, which is displayed on the left side of the screen.3. The Diagnostic Menu screen is displayed. The right side of the Diagnostic Menu displays the options for
running diagnostic test:v Test Number: Enter the four digit diagnostic number, or use Test Name to select a test.v Test Name: Choose the diagnostic name from the pull-down list.v Test Count: Enter the number of repetitions of the diagnostic to be run.v Test Status: Displays the status of the diagnostic.v Test Results: Displays the output of the diagnostic.v Run Button: Select this button to start the diagnostic.v Stop Button: Select this button to stop running the diagnostic.
Chapter 2. Diagnostic Tools 284
Using the Diagnostic Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283). The operator
panel displays the Diagnostic Menu:DIAG MENUTEST = 1.0<0.0.
2. To enter a test number, do the following.
Note: The “<” character indicates (points to) the current number position that can be changed.a. Press Value ↑ or Value ↓ to change the second number.b. Press Item ↑ or Item ↓ to move to the third number position.c. Press Value ↑ or Value ↓ to change the third number.
Note: For the Infoprint 21, the first number should always be a “1” and the last number shouldalways be a “0”.
3. Press Enter to run the diagnostic.
Chapter 2. Diagnostic Tools 285
Diagnostic TestsThe following table list the diagnostic tests that are available for the Infoprint 21.Table 90. Diagnostic Test Routines
TestRoutine Component Comments
1010 Test Print Prints MCU test print -- controller not involved
1020 Sensor/Switch Test Displays OK after switch changes state
1030 Fuser Temperature Returns temperature in degrees Celsius (C).
1040 Fuser Set Temperature Returns temperature in degrees Celsius (C).
1050 ROM Check Sum
1100 Main Motor
1110 ROS Motor Speed depends on current resolution.
1120 Fan Motor High
1130 Exit Motor CW
1140 Exit Motor CCW Low
1150 Exit Motor CCW High
1160 Duplex Motor Low
1170 Duplex Motor High
1180 OCT Motor
1200 Tray 1 Pick Clutch
1220 Tray 2 Pick Clutch
1240 Tray 3 Pick Clutch
1250 Tray Feed Clutches
1260 Aux Tray Solenoid
Chapter 2. Diagnostic Tools 286
Table 90. Diagnostic Test Routines (continued)
TestRoutine Component Comments
1270 Env Pick Clutch
1280 Registration Roll Clutch
1290 Offset
1300 Charge Roll AC
1310 Charge Roll DC
1320 Developer Bias AC
1330 Developer Bias DC
1340 Transfer Roll (-)
1350 Transfer Roll (+)
1360 Detack Saw
1370 Laser Diode Warning -- Can damage drum if left on.
1380 Option Direction Will only run once.
1390 Pressure Roller DC Bias
Chapter 2. Diagnostic Tools 287
Factory Adjust MenuThe Factory Adjust Menu allows you to change factory settings in the printer. The following sections describe howto run diagnostics using either a CE laptop PC attached to the Infoprint 21 serial Service Port or the Infoprint 21operator panel.
Note: Do not change values in the Factory Adjust Menu (except for serial number or registration adjustments)unless IBM Technical Support instructs you to do so.
Using the Factory Adjust Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Factory Adjust Menu link, which is displayed on the left side of the screen.3. The Factory Adjust Menu screen displays. The right side of the Factory Adjust Menu displays a table showing
the adjustments that can be made to different parameters.4. To change an adjustment value, enter or select a new value and then select the Apply button on the menu.
You can use the Cancel button to clear any entered values.
Using the Factory Adjust Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.
DIAG MENUTEST = 1.0<0.0.
3. Press the Menu ↑ or Menu ↓ key until FACTORY ADJ MENU is displayed.4. Press the Item ↑ or Item ↓ key to scroll through the factory adjustments and their current values.
Note: The current value is indicated by an asterisk (*) following the value.5. Press the Value ↑ or Value ↓ key to change the current value.6. Press Enter to change the current value to the new displayed value. An asterisk (*) appears next to the value
to indicate that it is now the current value.
Chapter 2. Diagnostic Tools 288
Factory Adjustment ParametersThe following table describes the factory adjustment parameters that can be changed.Table 91. Factory Adjustment Parameters
Adjustment Name Operator Panel Text Possible Values
Serial Number S/N 00-00000 *Note: Values entered using the operator panel aresimilar to Diagnostic tests with the arrow indicatingthe position to enter data.
00-00000 to 99-99999
Resolution Adjustment RES ADJ= * 600, 1200
Laser Diode Power Adjustment LASER= 8 * 0-15
Fuser Standby Temp FUSERSTBY= 8 * 0-8
Fuser Running Temp FUSERRUN= 8 * 0-15
Fuser Cleaning Temp FUSERCLEAN= 7 * 0-15
Registration Adj, Lead Edge, Tray 1 REG LEAD 1= 8 * 0-15
Registration Adj, Side to Side, Tray 1 REG SIDE 1= 4 * 0-15
Registration Adj, Lead Edge, Tray 2 REG LEAD 2= 8 * 0-15
Registration Adj, Side to Side, Tray 2 REG SIDE 2= 4 * 0-15
Registration Adj, Lead Edge, Tray 3 REG LEAD 3= 8 * 0-15
Registration Adj, Side to Side, Tray 3 REG SIDE 3= 4 * 0-15
Registration Adj, Lead Edge, MBF REG LEAD M= 8 * 0-15
Registration Adj, Side to Side, MBF REG SIDE M= 4 * 0-15
Paper Size Adj, MBF PPR SIZE M= * Paper types/sizes
Registration Adj, Lead Edge, Envel REG LEAD E= 8 * 0-15
Registration Adj, Side to Side, Envel REG SIDE E= 4 * 0-15
Paper Size Adj, Envel PPR SIZE E= * Paper types/sizes
Chapter 2. Diagnostic Tools 289
Chapter 2. Diagnostic Tools 290
Test Print MenuThe Test Print Menu allows you to print various types test print patterns using any of the possible input trays,output bins, and processing options (such as offsetting) that are available on the printer. The following sectionsdescribe how to print test prints using either a CE laptop PC attached to the Infoprint 21 serial Service Port or theInfoprint 21 operator panel.
Using the Test Print Menu from the CE Laptop PC:1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Test Print Menu link, which is displayed on the left side of the screen.3. The Test Print Menu screen displays. The right side of the Test Print Menu displays the options that can be
selected for printing test prints. To change any option, enter or select a new value.4. Select the Run button on the menu to print the test print with the selected options.
Note: The Stop button will cancel the test print that is in progress.
Using the Test Print Menu from the Operator Panel:1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.
DIAG MENUTEST = 1.0<0.0.
3. Press the Menu ↑ or Menu ↓ keys until TEST PRINT MENU is displayed.4. Press the Item ↑ or Item ↓ key to scroll through the test print options and their current values.
Note: The current value is indicated by an asterisk ″*″ following the value. See Table 92 on page 292 for adescription of the test print options.
5. Press the Value ↑ or Value ↓ keys to change the current value of a test print option.6. Press Enter to change the current value to the new displayed value.
Note: An asterisk (*) will appear next to the displayed value to indicate that it is now the current value.7. Select the RUN TEST PRINT item from the TEST PRINT MENU and press the Enter key to print the selected
test print and options.
Chapter 2. Diagnostic Tools 291
Test Print OptionsThe following table shows the test print options and values that are available on the Infoprint 21.Table 92. Test Print Options
Laptop Text withDefaults
Operator Panel Textwith Defaults
Possible Values Note
Print Type: SERVICE TYPE= SERVICE * SERVICE, ERROR LOG,WHITE, BLACK, GRID,PRINT QUALITY
v SERVICE: Similar to the Printer Configurationpage except NIC information is not shown.
v ERROR LOG: An error log containing the last 25errors with print count.
v WHITE: An all white page used for diagnosingprint quality problems
v BLACK: An all black page used for diagnosingprint quality problems
v GRID: A grid pattern across the entire page usedfor diagnosing print quality problems
v PRINT QUALITY: A sample print with patternsused for diagnosing print quality problems
Number of prints: 001 PRINTS=1 * 001 - 999 Enter up to three digits to specific the number oftest prints to print. TYPE=BLACK will only print 1black print.
Paper Source: Tray 1 SOURCE= TRAY 1 * TRAY 1, TRAY 2, TRAY3, AUX TRAY,ENVELOPE
TRAY 2, TRAY 3, and ENVELOPE are displayedonly if they are installed.
Paper Output: Main OUTPUT= MAIN * MAIN, OFFSET OFFSET is displayed only when the Offset OutputBin is installed.
Duplex: Off DUPLEX= OFF * OFF, ON This menu item is displayed only when the duplexunit is installed.
Offset: Off OFFSET= OFF * OFF, ON This menu item is displayed only when the OffsetOutput Bin is installed.
Chapter 2. Diagnostic Tools 292
Table 92. Test Print Options (continued)
Laptop Text withDefaults
Operator Panel Textwith Defaults
Possible Values Note
Offset Count: 01 OFFSET_CNT= 1 * 01 - 99 This menu item is displayed only if the OffsetOutput Bin is installed. Use up to two digits to enterthe value.
RUN TEST PRINT This menu item is only available from the operatorpanel. Select this item and press Enter to print theselect test print and options.
Chapter 2. Diagnostic Tools 293
Error LogThe Infoprint 21 error log can be displayed on the CE laptop PC attached to the printer’s serial Service Port,however the error log cannot be displayed on the operator panel. To display the error log on the CE laptop,access Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281) and select the ErrorLog link, which is displayed on the left side of the screen.
The error log can also be printed using the CE laptop PC attached to the Infoprint 21 serial Service Port or theoperator panel by selecting the Error Log item in the Test Print Menu (see “Using the Test Print Menu from theOperator Panel” on page 291). This printout will show the 25 most recent errors along with the page count atwhich the error occurred and a text description of the error. The errors are ordered with most recent error beingindex #1 and oldest error being index #25.
An abbreviated error log showing the 10 most recent errors is also printed on the Printer Configuration page andon Service Test Print item that can be selected in Service Mode from the Test Print Menu (see “Printing theService Page” on page 295).
Chapter 2. Diagnostic Tools 294
Printing the Service PageThe following sections describe how to print the Service Page using a CE laptop PC attached to the Infoprint 21serial Service Port or by using the Infoprint 21 operator panel.
Printing the Service Page from the CE Laptop PC1. Enter Service Mode (see “Accessing Service Mode from the CE Laptop PC” on page 281).2. Select the Test Print Menu link, which is displayed on the left side of the screen.3. The Test Print Menu screen displays. The right side of the Test Print Menu will display the options that can be
selected for printing test prints. Select Service for the print type item.4. Select and change any other items that you want to change from the default values.5. Select the Run button on the menu to print the test print with the selected options.
Note: The Stop button will cancel the test print that is in progress.
Chapter 2. Diagnostic Tools 295
Printing the Service Page from the Operator Panel1. Enter Service Mode (see “Accessing Service Mode from the Operator Panel” on page 283).2. The operator panel displays the Diagnostic Menu.
DIAG MENUTEST = 1.0<0.0.
3. Press the Menu ↑ or Menu ↓ key until TEST PRINT MENU is displayed.4. Press the Item ↑ or Item ↓ keys until the TYPE item is displayed.5. If TYPE=SERVICE* is not displayed:
a. Press the Value ↑ or Value ↓ key until TYPE=SERVICE is displayed.b. Press Enter .
6. If you want to change other items to new values, do the following:a. Press the Item ↑ or Item ↓ keys to select the item.b. Press the Value ↑ or Value ↓ key to select the new value.c. Press Enter . An asterisk (*) will appear next to the displayed value to indicate that it is now the current
value.7. Select the RUN TEST PRINT item from the TEST PRINT MENU and press the Enter key to print the Service
Test print.
Note: If the test print does not print, press the Online key to display the error message.
Chapter 2. Diagnostic Tools 296
Chapter 3. Wiring and Pin-Out Diagrams
Master Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298Pin-Out Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . 299Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and to Fan Asm and Front Cover
Interlock Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and Fuser Asm . . . . . . . . . . . . . . 301Pin-Out Diagram D: MCU PCB to Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear Cover Interlock Switch . . . . . . . . . 303Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to Paper Low Photo Sensor and Lift
Control Photo Sensor, Pick Clutch, Feed Clutch, and Tray Lift Motor . . . . . . . . . . . . . . . . . . . . 304Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor, and Main Motor . . . . . . . . . 305Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor, Aux Pick-up Solenoid,
Registration Sensor, Registration Clutch, Toner Sensor, and Envelope PCB. . . . . . . . . . . . . . . . . 306Pin-Out Diagram J: MCU PCB to Laser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
© Copyright IBM Corp. 2000 297
Master Wiring DiagramPin-Out Diagram A: Pin-Out Diagram B: Pin-Out Diagram C: Pin-Out Diagram D: Pin-Out Diagram E:Pin-Out Diagram F: Pin-Out Diagram G: Pin-Out Diagram H: Pin-Out Diagram J:
HA
K31
4
MCU PCB
Paper SizePCB
(Tray 1)
Offset FullStack Sensor
Offset ExitSensor
Offset PCB
Offset MechanismMotor
EnvelopeExit
Sensor
EnvelopeNo-PaperSensor
EnvelopeClutch
Envelope PCB
Offset DriveMotor
DuplexFace-UpSensor
Duplex Motor
Duplex PaperSensor
Duplex PCB
Offset DirectionSolenoid
Offset DirectionHome Sensor
No-Paper SensorFeed PCB
InterfacePCB
AUXNo-PaperSensor
Feed ClutchTray LiftMotorPick Clutch
HVPS
CR
DB
TR
DST
Fuser Asm
BTRAsm
TonerCartridge
ExitSensor
Heater Lamp
PRB
LaserAsm
Lift ControlSensor
Low PaperSensor
AUX PickSolenoid
MM
MM
RegistrationSensor
RegistrationClutch
Front CoverInterlockSwitch
Fan Motor
AC
5 V DCPCB
ControllerPCB
OperatorPanel
LVPS
P351
P341
P/J61
P/J66
P/J451
P/J45
P/J43
P/J432
P/J433
P/J41
P/J661 P/J662 P/J651 P/J641P/J672P/J673
P/J65 P/J64 P/J67
P531J541
P/J209
P/J39
P/J360
P/J37
P/J38
P/J412
P/J415 P/J416
P/J414
P/J288
P/J413
P/J361
P/J35
P/J22
P/J25
P/J26
P/J27
P/J9P
6J
36
P/J282
P/J11
P/J281
P/J283
P/J284
P/J285
P/J1
P/J101
P/J28
P/J4
P/J261
P/J271
P/J262
P/J223
P/J213
P/J211
P/J212
P/J21
P/J33
P/J331
P/J51
P/J34
P/J418
P/J411
J202
P/J225
P/J226
P/J227
P/J417
P/J228
P/J224
P/J223 P/J210
J391
P/J231
P/J23
TonerSensor
P/J421
P/J42
Toner CartridgeKey Sensor
P/J251
Full StackPhotoSensor
Rear CoverInterlockSwitch
P/J31
P/J30
P/J311
Feed PCB Feed PCB
Option PaperSize PCB(Tray 3)
Option PaperSize PCB(Tray 2)
Paper SizeSensor
Paper SizeSensor
Paper SizeSensor
P/J53
P/J54
P/J61 P/J61
P/J53
P/J52
M
ExitMotor
MainMotor
M P/J32
P/J29
P/J44
P511J521
F
J
H
E
E
G
G
G
C
C
C
D
A
B
B
B
B
B
A
H
F
Alphabetical Character on Wire Represents Pin-Out Diagrams
Chapter 3. Wiring and Pin-Out Diagrams 298
Pin-Out DiagramsThe pin-out diagrams illustrate the electrical relationships between printer components. Each pin-out wire has asignal name, and is terminated at both ends with a connector-pin number. The connector number is listed at thetop of the connector. The Master Wiring Diagram shows electrical connections within the printer.
Pin-Out Diagram A: LVPS PCB to MCU PCB and Fuser Asm
LVPS PBCMCU PBC
Fuser Asm
FAN ON/HEAT
/FHIGH3.3V
FAN ALARMGND5V
24V RTN24V RTN24V RTN
24V24V24V
AC HOTAC NUT
1413121110
987654321
1413121110987654321
12
P/J281
P/J11 P/J271
P/J28
HK
E00
1FA
Chapter 3. Wiring and Pin-Out Diagrams 299
Pin-Out Diagram B: LVPS PCB to +5 V DC PCB to Controller PCB and toFan Asm and Front Cover Interlock SwitchMaster Wiring Diagram
5 V DC PCBController PCB
LVPS
24V24V
RTN24V
GND3.3V
GND5V
24VFAN ALRM
RTN
123
12
21
43
21
21
P/J283
P/J284
Fan Asm
Front CoverInterlockSwitch
P/J1
P/J282
P/J288P/J19
P101
HK
E00
2FA
Chapter 3. Wiring and Pin-Out Diagrams 300
Pin-Out Diagram C: MCU PCB to HVPS PCB to Drum, BTR Asm, and FuserAsmMaster Wiring Diagram
HVPSMCU PCB
CR-DRCR-ACCR-CHDB-DATR(-)TR(+)
DB. DCDTS
TR-A/DTR-D/AGND3.3VRTN24VPRB
CRDB
Toner Cartridge
Drum
FG
BCR
Mag Roll
BTR Asm
BTRTR
DTS
Fuser Asm
PRB
123456789
101112131415
151413121110987654321
P/J261
P/J271
P/J26
HK
E00
3FA
Chapter 3. Wiring and Pin-Out Diagrams 301
Pin-Out Diagram D: MCU PCB to Fuser AsmMaster Wiring Diagram
543
MCU PCB Fuser Asm
/EXITGND3.3V
/EXIT(IN)GND3.3V
STS(A/D)GND
STS(A/D)GND
543
21
123
123
12
45
21
P/J27
Exit Sensor
STS
P/J275
P/J274
HK
E00
4FA
P/J271
Chapter 3. Wiring and Pin-Out Diagrams 302
Pin-Out Diagram E: MCU PCB to Full Stack Photo Sensor and Rear CoverInterlock SwitchMaster Wiring Diagram
MCU PCB
/FSTKGND3.3V
24V EXIT MOT24V
123
321
21
P/J311
Full StackPhoto Sensor
Rear CoverInterlock Switch
P/J31
P/J30
HK
E00
5FA
Chapter 3. Wiring and Pin-Out Diagrams 303
Pin-Out Diagram F: MCU PCB to Paper Size PCB to Feed PCB to PaperLow Photo Sensor and Lift Control Photo Sensor, Pick Clutch, FeedClutch, and Tray Lift MotorMaster Wiring Diagram
3.3VGND
LOW PAP1/TG MCUFD TXDFD RXD/FEED3/FEED2
/NO PAP3/NO PAP2
/LOW PAP3/LOW PAP2
3.3VGND24V
24V RTNReserved
/Feed1/NO PAP1/LOW PP1
3.3VGND
NUD LOW
FEED1 ON
/TRNC(OUT)24V I/L
24V I/L
24V
NUD MOTOR
24V I/L
321
321
4321
7654321
7654321
1234
12
12345
123
1234567891011121314151617
1716151413121110
987654321
456
P/J661
P/J662
P/J651
P/J672P/J673
P/J65
P/J64
P/J67
Paper LowPhoto Sensor
No-PaperPhoto Sensor
MCU PCB
Paper Size Sensors
Paper Size PCB
Feed PCB
Option Paper Drawer
P/J51
Lift ControlPhoto Sensor
PickClutch
FeedClutch
Tray Lift Motor
P/J66P/J331 P/J33
P/J61
HK
E00
6FA
Chapter 3. Wiring and Pin-Out Diagrams 304
Pin-Out Diagram G: MCU PCB to Toner Cartridge Key Sensor, Exit Motor,and Main MotorMaster Wiring Diagram
5V5V LD/CRUGND
/EXIT XB/EXIT XA/EXIT B/EXIT A
24V EXIT MOT
/M RSV/MARM
/MMOT ON24V RTN24V RTN24V RTN
24V24V24V
4321
1234
54321
987654321
P/J25 P/J251
P/J32
P/J29
Toner Cartridge Key Sensor
Exit Motor
Main Motor
MCU PCB
HK
E00
7FA
Chapter 3. Wiring and Pin-Out Diagrams 305
Pin-Out Diagram H: MCU PCB to Interface PCB to Aux No-Paper Sensor,Aux Pick-up Solenoid, Registration Sensor, Registration Clutch, TonerSensor, and Envelope PCBMaster Wiring Diagram
/NO PRM3.3V NOPRM
/SOLM/REG
3.3V REG/REG CL/TONER
GND24V
24V RTN/EPRS
/NOPRE3.3V
SOLE
/NO PRMGND3.3V
/SOLM24V
/REGGND3.3V
/REG CL
24V
/TONER24V
RTN/EPRS/NOPRGND3.3V
SOLE(OUT)24V
24V RTN
16151413121110987654321
123456789
10111213141516
321
4321
7654321
543
2
1
123
1234
1234
21
123
P/J23 P/J231P/J45
P/J44
P/J43
P/J421
P/J418
P/J42
P41
P/J432
P/J433
P/J451
Aux No-Paper Sensor
Aux Pick-Up Solnoid
Registration Sensor
Registration Clutch
Toner Sensor
Envelope Connector
Envelope PCB
MCU PCB Interface PCB
HK
E00
8FA
Chapter 3. Wiring and Pin-Out Diagrams 306
Pin-Out Diagram J: MCU PCB to Laser AsmMaster Wiring Diagram
P.DATA/nP.DATA
Differential
/LD/LDEN
Vmf(D/A)GND5VLD
SG/SOS(IN)
5V
24V24V RTN
/RMOT(OUT)
/RCLK(OUT)
12
123456
789
101112
13
21
654321
321
54321
P/J22
P/J21
P/J223
P/J213
P/J211
P/J212
Laser AsmMCU PCB
HK
E00
9FA
Chapter 3. Wiring and Pin-Out Diagrams 307
Chapter 4. Locations
Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310Major Assemblies, Components, and Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312PCBs (Printed Circuit Boards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
© Copyright IBM Corp. 2000 308
Controller
Item Ref
HA
K31
6
9
1
8
7
6
5
4
3
2Controller PCB 1
Code Compact Flash Slot 2
Memory DIMM Slots 3
IPDS Compact Flash Slot 4
NIC (Network InterfaceCard)
5
Hard Drive Connector 6
Service (Serial) Port 7
Font Compact Flash Slot 8
Parallel Port 9
Chapter 4. Locations 309
Covers
Item Ref
5
1
2
3
4
HA
K30
9
6
7
8
Exit Cover 1
Top Cover 2
Front Cover Asm 3
Right Cover 4
Front Left Cover 5
Controller Cover 6
Left Cover 7
Rear Cover Asm (WithFace-Up Bin), Rear CoverAsm (Without Face-UpBin)
8
Chapter 4. Locations 310
Major Assemblies, Components, and Supplies
Item Ref
5
1
2
7
6
3
4
HA
K31
8
Fan Motor 1
Toner Cartridge 2
ROS Asm (Laser) 3
Main Motor 4
Gear Drive Asm 5
Bias Transfer Roll 6
Fuser Asm 120 v, FuserAsm 230 v
7
Chapter 4. Locations 311
Optional Features
Item Ref
HA
K30
6
4
5
1
3
2
Offset Asm 1
Env Tray Asm 2
Option Paper Drawers 3
Duplex Asm 4
Rear Cover Asm (WithFace-Up Bin), Rear CoverAsm (Without Face-UpBin)
5
Chapter 4. Locations 312
PCBs (Printed Circuit Boards)
Item Ref
5
6
7
8
9
1
2
3
4
HA
K31
9
Controller PCB 1
MCU PCB 2
5 V DC PCB 3
Main Motor 4
Interface PCB 5
HVPS 6
Feed PCB 7
Paper Size PCB 8
LVPS 120V, LVPS 230V 9
Chapter 4. Locations 313
RollersItem Ref
7
5
4
6
8
3
2
3
2
3
2
19 18
17
16
1311
12
11
10
11
9
14
151
1
1
HA
K31
2
Pick Roll Asm 1
Tray Retard Roll 2
Feed Roll Asm 3
Aux Pick Roll 4
Rubber Registration Roll 5
Metal Registration Roll 6
Toner Cartridge 7
Bias Transfer Roll 8
Fuser Asm 120 v, FuserAsm 230 v
9
Exit Roll 1 10
Exit Pinch Roll 11
Exit Roll 2 12
Exit Roll 3 13
Duplex Roll 14
Duplex Drive Belt 15
Offset Roll 16
Offset Pinch Roll 17
Offset Exit Roll 18
Offset Exit Pinch Roll 19
Chapter 4. Locations 314
Sensors and SwitchesItem Ref
7
5
4
6
8
3
2
13
14
14
14
15
15
15
12
1110
9
1
1
1 HA
K31
3
Lift Control Photo Sensor 1
Paper Size Sensor Asm 2
Aux No-Paper PhotoSensor
3
Registration Sensor 4
Fuser Exit Sensor 5
Full Stack Photo Sensor 6
Offset Exit Photo Sensor 7
Offset Full Stack PhotoSensor
8
Duplex Paper PhotoSensor
9
Front Cover InterlockSwitch
10
Rear Cover InterlockSwitch
11
Duplex Face-up PhotoSensor
12
Toner Cartridge KeySensor
13
No-Paper Photo Sensor(Feed PCB)
14
Paper Low Photo Sensor 15
Chapter 4. Locations 315
Chapter 5. Removals and Replacements
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Text and Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3255v DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326Aux Drive Gear Shaft and Aux Drive Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327Aux No Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328Aux No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332Aux Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333Aux Pick Up Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335Aux Pick Up Gear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337Aux Pick Up Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338Aux Retard Pad Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342Aux Tray Bottom Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343Bearing and Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 347Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350Duplex Bottom Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351Duplex Connector Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352Duplex Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353
© Copyright IBM Corp. 2000 316
Duplex Face Up Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354Duplex Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355Duplex Motor Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 356Duplex Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357Duplex PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358Duplex Roll Retaining Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359Duplex Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360Duplex Upper Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361ENV Arm Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362ENV Bottom Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 363ENV Clutch (Electric). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364ENV Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366ENV Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367ENV Gear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368ENV Large Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369ENV No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370ENV No Paper Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371ENV Retard Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372ENV Roll Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373ENV Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375ENV Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376ENV Tray Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 377ENV Tray Pinch Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384Face-Up Chute. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
Chapter 5. Removals and Replacements 317
Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 389Feed Tray Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392Front Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 393Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 396Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397Fuser Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398Fuser Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400Harness (J27, J11, J262 - J271) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401Harness (J34-P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408Left Handle Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410Lift Control Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 411LVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415Metal Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416Middle Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 417No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
Chapter 5. Removals and Replacements 318
Offset Direction Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422Offset Drive Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423Offset Exit Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424Offset Exit Bin Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 425Offset Exit Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428Offset Inner Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429Offset Inner Chute Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 430Offset Lower Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431Offset Mechanism Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 432Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433Offset PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434Offset Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435Offset Tray Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 436Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437Option Chute Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 440Option Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441Option Gear Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442Option Harness (J52-J521) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 443Option Harness (J53-531) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446Option Lift Control Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447Option No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449Option Paper Low Photo Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450Option Paper Size Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 451Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 452
Chapter 5. Removals and Replacements 319
Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 453Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 454Option Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459Option Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460Option Top Front Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 461Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 462Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463Paper Size Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464Paper Size Housing Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465Paper Sizing PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466PCB Cover Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468Pick Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 470Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471Rear Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 474Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 476Rear Duplex Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 477Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 479Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 480Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 481Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 482Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 483Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 484ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 485Rubber Registration Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 486Rubber Registration Roll Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 489Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 490
Chapter 5. Removals and Replacements 320
Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 491Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 492Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493Tray Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 494Tray Lift Motor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 496Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 498Tray Retard Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 502
Chapter 5. Removals and Replacements 321
General Information
Text and IllustrationsNumeric callouts in text are enclosed in parentheses. Unless otherwise noted, all text callouts refer to theillustration to the left of that text.
Printer orientation is defined as follows.
Chapter 5. Removals and Replacements 322
Preparation1. Power off and unplug the printer.2. Remove the 550-Sheet Tray Asm.3. Open the Front Cover.4. Remove the Toner Cartridge and store it in a dark, safe place that is free from direct sunlight.5. When working near the Fuser Asm, wait until the Fuser Asm is cool.
CAUTION:
<2-43> High temperature; switch off the printer and allow at least 30 minutesfor parts in this area to cool before handling.
hcsf
0243
6. Disconnect all interface cables from the rear panel of printer.7. To eliminate static electricity, wear wristbands or another grounding device. See “Electrostatic Discharge (ESD)
Procedures” on page 26.
Chapter 5. Removals and Replacements 323
Removal and Replacement Procedures
Chapter 5. Removals and Replacements 324
550-Sheet Tray AsmParts Reference: 550-Sheet Tray Asm
Removal :1. Slide the 550-Sheet Tray Asm (1) from the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 325
5v DC PCBParts Reference: 5 V DC PCB
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect P/J288 from the 5V DC PCB (1).5. Disconnect P/J101 from the 5V DC PCB.6. Remove the two screws (2) that hold the 5V DC
PCB to the printer.7. Remove the 5V DC PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 326
Aux Drive Gear Shaft and Aux Drive GearParts Reference: Aux Drive Gear Shaft and Aux DriveGear
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Hold the Aux Drive Gear (1) and remove the Aux
Drive Gear Shaft (2).6. Remove the Aux Drive Gear.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 327
Aux No Paper Actuator
1
32
HK
A01
2FD
Parts Reference: Aux No Paper Actuator
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release two hooks (2) and open the Aux Tray
Bottom Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).
Continued on p. 329.
Chapter 5. Removals and Replacements 328
Parts Reference: Aux No Paper Actuator
Continued from p. 328.10. Remove the Aux No Paper Actuator (2) from the
back of the Aux Tray Bottom (1).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 329
Aux No Paper Photo Sensor
1
32
HK
A01
2FD
Parts Reference: Aux No Paper Photo Sensor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hooks and open the Aux Tray Bottom
Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).
10. Remove the Aux Tray Bottom Spring (3) from theAux Tray Asm.
Continued on p. 331.
Chapter 5. Removals and Replacements 330
Parts Reference: Aux No Paper Photo Sensor
Continued from p. 330.11. Disconnect P/J451 (4) from the Aux No Paper
Photo Sensor (5).12. Release the hooks of the Aux No Paper Photo
Sensor, and remove the Aux No Paper Sensor fromthe Aux Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 331
Aux Pick Roll
1 2
HK
A00
9FB
Parts Reference: Aux Pick Roll
Removal :1. Open the Front Cover Asm (p. 391).2. Unhook the latch on the right Aux Pick Roll Core (2)
and move it to the right.3. Move the Aux Pick Roll (1) to the right, then raise it
upward to remove from the Aux Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 332
Aux Pick Roll Asm
1
HK
A0Y
3FB
2
3
Parts Reference: Aux Pick Roll
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Unhook the Aux Pick Roll Right Cam (1) and move it
to the left.8. Unhook the Aux Pick Roll Left Cam (2) and move it
to the right.
Continued on p. 334.
Chapter 5. Removals and Replacements 333
Parts Reference: Aux Pick Roll
Continued from p. 333.9. Align the pin on the Aux Pick Roll Asm (3) with the
left slit of the Aux Tray Asm. Then slide the AuxPick Roll Asm to the left and remove the right shaftof the Aux Pick Roll Asm from the Aux Tray Asm.
10. Lift the right shaft of the Aux Pick Roll Asm andslide the Aux Pick Roll Asm to the right to remove itfrom the Aux Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 334
Aux Pick Up GearParts Reference: Aux Pick Up Gear
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Unhook and remove the Aux Pick Up Gear (1) from
the Aux Pick Roll Shaft.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 335
Aux Pick Up Gear SpringParts Reference: Aux Pick Up Gear Spring
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Unhook the Aux Pick Up Gear Spring (1) from the
Aux Pick Up Gear (2) and from the hole in the AuxTray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 336
Aux Pick Up Pad AsmParts Reference: Aux Pick Up Pad Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release two hooks and open the Aux Tray Bottom
Asm (1).9. Rotate the Aux Pick Up Pad Asm (3) by 90 degrees
to the front and remove the Aux Pick Up Pad Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 337
Aux Pick Up SolenoidParts Reference: Aux Pick Up Solenoid
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the one screw (1), and then remove the Aux
Pick Up Solenoid (2) from the Aux Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 338
Aux Retard Pad Asm
1
32
HK
A01
2FD
Parts Reference: Aux Retard Pad Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hooks and open the Aux Tray Bottom
Asm (1).
Continued on p. 340.
Chapter 5. Removals and Replacements 339
Parts Reference: Aux Retard Pad Asm
Continued from p. 339.9. Remove the Aux Pick Up Pad Asm (p. 337).
10. Release the left and right brackets of the AuxRetard Pad Asm (3) from the Aux Tray Asm. (2)and remove the Aux Retard Pad Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 340
Aux TrayParts Reference: Aux Tray
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the E-clip (3) that holds the Aux Tray Stop
to the Aux Tray (1).3. Insert a small screwdriver between the Aux Tray and
the Front Cover Asm as shown, and remove the AuxTray right peg from the Front Cover Asm.
4. Use the small screwdriver to release the Aux Trayleft peg from the Front Cover Asm.
5. Align the peg of the Aux Tray Stop (2) with the slit inthe Aux Tray, and then remove the Aux Tray from theFront Cover Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 341
Aux Tray AsmParts Reference: Aux Tray Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Disconnect the following three connectors (1) from
the Interface PCB:v P/J41v P/J44v P/J45
5. Release the two clamps (not shown) that hold theharnesses of the Aux Tray Asm (2) to the printer.
6. Remove the four screws (3) that hold the Aux TrayAsm to the printer.
7. Remove the Aux Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 342
Aux Tray Bottom Asm
13
2
HK
A01
2FE
Parts Reference: Aux Tray Bottom Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Pick Up Gear Spring (p. 336).6. Remove the Aux Pick Up Gear (p. 335).7. Remove the Aux Pick Roll Asm (p. 333).8. Release the hook (2) and open the Aux Tray Bottom
Asm (1).9. Remove the Aux Pick Up Pad Asm (p. 337).
Continued on p. 344.
Chapter 5. Removals and Replacements 343
Parts Reference: Aux Tray Bottom Asm
Continued from p. 343.10. Use a screwdriver to unhook the right bearing (2).11. Use a screwdriver to unhook the left bearing (4).12. Remove the Aux Tray Bottom Asm (1) from the Aux
Tray Asm (3).13. Remove the bearings from the left and right shafts
of the Aux Tray Bottom Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 344
Bearing and Exit Roll 23
23
1
HK
A04
0FB
Right
Left
Parts Reference: Exit Roll 2
Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the Rear Cover Interlock Switch (p. 475).3. Lift the tab on Exit Gear-17 (1) and slide Exit
Gear-17 from the Exit Roll 2 (2).4. Use a small screwdriver to remove the left and right
bearings (3) from the Exit Asm.5. Remove the Exit Roll 2 from the Exit Asm.
Note: When the Exit Roll 2 is removed, the two ExitPinch Rolls fall out.
6. Remove the left and right Bearings from Exit Roll 2.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 345
Bias Transfer RollParts Reference: Bias Transfer Roll
Notes:1. In the following procedures, do not touch the surface
of the Bias Transfer Roll or the Detack Saw of theBTR Support Asm.
! CAUTION:
<2-24> Sharp edges exist in this area. hcsf
0224
2. When removing the Bias Transfer Roll from theprinter, take care not to damage the roll.
3. After removing the Bias Transfer Roll, roll it in paperand store it in a safe place.
4. When replacing the Bias Transfer Roll with a newone, peel off the paper that protects the roll of thenew Bias Transfer Roll before mounting.
Removal :1. Open the Front Cover Asm.2. Remove the Toner Cartridge.3. Push to unlock the left and right latches of the BTR
Asm (1) that hold the Bias Transfer Roll to theprinter.
4. Hold the left and right knobs of the Bias TransferRoll and remove the Bias Transfer Roll from the BTRAsm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 346
BTR Support Asm
2
1
4
4
3
HK
A03
4FC
Parts Reference: BTR Support Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the one screw (1) that attaches the DTS
Wire to the BTR Support Asm (2).10. Remove the one screw (3) that attaches the TR
Wire to the BTR Support Asm.11. Remove the two screws (4) that hold the BTR
Support Asm to the printer.12. Remove the BTR Support Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 347
Controller CoverParts Reference: Controller Cover
Removal :1. Loosen the two thumbscrews (1) that hold the
Controller Cover (2) to the printer.2. Remove the Controller Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 348
Controller PCB
3
3 HK
A0Y
6FB
2
2
2
RightLeft
1
Parts Reference: Controller PCB
Removal :1. Remove the Controller Cover (p. 348).2. Disconnect P/J9 from the Controller PCB (1).3. Disconnect P/J4 from the Controller PCB.4. Remove the five screws (2) that hold the Controller
PCB to the printer.5. Remove the five screws (3) that hold the rear bezel
to the printer.6. Move the Controller PCB to the rear and disconnect
the connector P/J6 from the printer.7. Remove the Controller PCB.
Note: The Controller PCB replacement part may notcome with a mounting bezel. If it does not include amounting bezel, remove the bezel from the originalpart and install it on the replacement part.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 349
Duplex Asm
HK
A0D
0FC
1
Right
Left
Parts Reference: Duplex Asm
Removal :1. Open the Rear Cover.2. Push in the left and right levers (1) of the Duplex
Asm and remove the Duplex Asm from the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 350
Duplex Bottom Cover
1
HK
A0F
0FB
Bottom
Top
Parts Reference: Duplex Bottom Cover
Removal :1. Remove the Duplex Asm (p. 350).2. Release the hooks that hold the Duplex Bottom
Cover (1) to the Duplex Asm.3. Remove the Duplex Bottom Cover from the Duplex
Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 351
Duplex Connector AsmParts Reference: Duplex Connector Asm
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Disconnect connector P/J39 (1) from the Duplex
PCB.5. Release the harness of the Duplex Connector Asm
from the three hooks of the Duplex Asm.6. Remove the two screws (2) that hold the Duplex
Connector Asm (3) to the Duplex Asm.7. Slide the harness of the Duplex Connector Asm from
the hole in the Duplex Asm.8. Remove the Duplex Connector Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 352
Duplex Drive BeltParts Reference: Duplex Drive Belt
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the Duplex Roll Retaining Clip (p. 359).8. Remove the Duplex Drive Belt (1) from the gears of
the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 353
Duplex Face Up Photo SensorParts Reference: Duplex Face-up Photo Sensor
Removal :1. Remove the Duplex Asm (p. 350).2. Release the hooks and remove the Duplex Face Up
Photo Sensor (1) from the Duplex Asm.3. Disconnect connector P/J361 (2) from the Duplex
Face Up Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 354
Duplex MotorParts Reference: Duplex Motor
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Disconnect connector P/J38 (1) from the Duplex
PCB.5. Release the Duplex Motor harness from the two
hooks of the Duplex Asm.6. Remove the two screws (3) and remove the Duplex
Motor (2) from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 355
Duplex Motor CoverParts Reference: Duplex Motor Cover
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the two screws (1) and remove the Duplex
Motor Cover (2) from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 356
Duplex Paper Photo Sensor
2
1
HK
A0F
1FB
Bottom
Top
Parts Reference: Duplex Paper Photo Sensor
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Disconnect connector P/J37 (1) from the Duplex
PCB.4. Release the hooks that hold the Duplex Paper Photo
Sensor (2) to the Duplex Asm and remove theDuplex Paper Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 357
Duplex PCBParts Reference: Duplex PCB
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Release the hook that holds the Duplex PCB (1) to
the Duplex Asm and remove the Duplex PCB.4. Disconnect the following connectors from the Duplex
PCB.v P/J36v P/J37v P/J38v P/J39
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 358
Duplex Roll Retaining ClipParts Reference: Duplex Roll Retaining ClipNote: This procedure describes how to remove all threeDuplex Roll Retaining Clips. Only remove the ones youneed to remove.
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Release the hook on the rear Duplex Roll Retaining
Clip (1) and remove the Duplex Roll Retaining Clip.7. Release the hook on the middle Duplex Roll
Retaining Clip (2) and remove the Duplex RollRetaining Clip.
8. Release the hook on the front Duplex Roll RetainingClip (3) and remove the Duplex Roll Retaining Clip.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 359
Duplex Top CoverParts Reference: Duplex Top Cover
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Press the two levers and open the Duplex Top Cover
(1).6. Release the right shaft of the Duplex Top Cover from
the bearing, and slide the Duplex Top Cover to theupper right from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 360
Duplex Upper GuideParts Reference: Duplex Upper Guide
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the two screws (1) and remove the Duplex
Upper Guide (2) from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 361
ENV Arm WeightParts Reference: Env Arm Weight
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the right side of ENV Arm Weight (1) from
the right shaft of the ENV Tray Asm (3).3. Remove the ENV Arm Weight and ENV Lower Arm
Weight (2) from the ENV Tray Asm.4. Remove the right side of ENV Arm Weight and from
the right shaft of ENV Weight Cover.5. Pull the right side of ENV Weight Cover to the front
and right, then remove the ENV Lower Arm Weight.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 362
ENV Bottom CoverParts Reference: Env Bottom Cover
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the two screws (1) and then remove the
ENV Bottom Cover (2) from the ENV Tray Asm.3. Remove the ENV Connector and Harness
(J411-J418) from the ENV Bottom Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 363
ENV Clutch (Electric)Parts Reference: Env Clutch - Electric
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375).4. Remove the ENV PCB.5. Remove the ENV Gear Cover (p. 368).6. Slide the ENV Clutch (Torque) (1) off of the shaft of
ENV Roll Shaft.
Continued on p. 365.
Chapter 5. Removals and Replacements 364
Parts Reference: Env Clutch - Electric
Continued from p. 364.7. Slide the Bearing (2) off of the shaft Clutch ELEC17
(3).8. Slide the ENV Clutch (Electric) (4) and Harness
(J413-J416) (5) off of the shaft of ENV Shaft Clutch(Electric).
9. Disconnect connector P/J416 (6) from the ENVClutch (Electric).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 365
ENV Connector - Female
HK
A06
8FD
4
1
2
3
Parts Reference: Env Connector - Female
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Slide the ENV Connector Plate (1) to the left and
remove it from the Aux Tray Asm (2).5. Remove the two screws (3) that hold the ENV
Connector (4) to the ENV Connector Plate. Thenremove the ENV connector.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 366
ENV Exit Photo SensorParts Reference: Env Exit Photo Sensor
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Release the two hooks that hold the ENV Exit Photo
Sensor (1) to the ENV Top Cover, and remove theENV Exit Photo Sensor.
5. Disconnect connector P/J417 (2) from the ENV ExitPhoto Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 367
ENV Gear CoverParts Reference: ENV Gear Cover
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Remove the ENV PCB. Parts like the gear and clutch will
easily drop when the cover is removed. Take care not tolose them.
5. Remove two screws (1) and remove the ENV Gear Cover(2) from the ENV Tray Asm.
6. Unhook the following harnesses from the ENV Gear Cover:v Harness (J413-J416) connected to the ENV Clutch
(Electric)v Harness (J414-J415) connected to the ENV No Paper
Photo Sensor7. Slide the following harnesses through the hole in the ENV
Gear Cover:v Harness (J411-J418) connected to the ENV Connectorv Harness (J413-J416) connected to the ENV Clutch
(Electric)v Harness (J414-J415) connected to the ENV No Paper
Photo Sensor
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 368
ENV Large Pinch RollParts Reference: Env Large Pinch Roll
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375)4. Remove the ENV Retard Roll Asm (p. 372).5. Remove the ENV Large Pinch Roll (1) from the ENV
Top Cover.6. Remove the bearings (2) from the shaft of ENV
Large Pinch Roll.7. Remove the rollers (3) from the shaft of ENV Large
Pinch Roll.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 369
ENV No Paper ActuatorParts Reference: Env No-Paper Actuator
Removal :1. Remove the ENV Tray Asm (p. 376)2. Remove the ENV Bottom Cover (p. 363)3. Release the shaft of the ENV No Paper Actuator (1)
from the the ENV Tray Asm, and remove the ENVNo Paper Actuator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 370
ENV No Paper Photo SensorParts Reference: Env No Paper Photo Sensor
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV No Paper Actuator (p. 370)4. Release the hooks and remove the ENV No Paper
Photo Sensor (1) from the ENV Tray Asm.5. Disconnect connector P/J415 (2) from the ENV No
Paper Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 371
ENV Retard Roll Asm
1
2
HK
A0N
1FB
Bottom
Top
Parts Reference: Env Retard Roll Asm
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375). Be careful not
to lose the ENV Retard Spring (2).4. Remove the shaft of ENV Retard Roll Asm (1) from
the bearing of the ENV Top Cover, and remove theENV Retard Roll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 372
ENV Roll ShaftParts Reference: ENV Roll Shaft
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Top Cover (p. 375).4. Remove the ENV PCB.5. Remove the ENV Gear Cover (p. 368).6. Slide the ENV Clutch (Torque) (1) off the ENV Roll
Shaft.
Continued on p. 374.
Chapter 5. Removals and Replacements 373
HK
A0N
5FB
24
3 5Parts Reference: ENV Roll Shaft
Continued from p. 373.7. Remove the Bearing (2).8. Move the ENV Roll Shaft (3) to the left and release
it from the right bearing (4) of the ENV Tray Asm.9. Lift the ENV Roll Shaft and remove it from the ENV
Tray Asm.10. Remove the bearing from the right ENV Roll Shaft.11. Remove the E-ring (5) from the right ENV Roll
Shaft.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 374
ENV Top CoverParts Reference: Env Top Cover
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the two screws (1) and then open the ENV
Top Cover (2).4. Disconnect connector P/J412 from the ENV PCB.5. Slide the ENV Top Cover to the left to remove it from
the the ENV Tray Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 375
ENV Tray Asm
1
HK
A0M
2FB
Parts Reference: Env Tray Asm
Removal :1. Slide the ENV Tray Asm (1) from the printer.2. Install the ENV Gear Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 376
ENV Tray ExtensionParts Reference: Env Tray Extension
Removal :1. Remove the ENV Tray Asm (p. 376).2. Remove the ENV Bottom Cover (p. 363).3. Remove the ENV Tray Pinch Roll (p. 378).4. Slide the ENV Tray Extension (1) from the ENV Tray
Asm in diagonal upward direction.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 377
ENV Tray Pinch RollParts Reference: Env Tray Pinch Roll
Removal :1. Remove the ENV Tray Asm (p. 376).2. Slide out the ENV Tray Extension (1).3. Use a small screwdriver to push the shafts of the
ENV Tray Pinch Rolls (2) out of the three rear holesof the ENV Tray Pinch Roll.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 378
Exit AsmParts Reference: Exit Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Controller Cover (p. 348).6. Remove the Left Cover (p. 408).7. Remove the Top Cover (p. 493).8. Remove the PCB Cover Plate (p. 467).9. Remove the Rear Cover Interlock Switch (p. 475).
10. Disconnect connectors P/J32 and P/J31 from theMCU PCB (p. 415).
11. Remove the four screws (1) that hold the Exit Asm(2) to the printer.
12. Remove the Exit Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 379
Exit CoverParts Reference: Exit Cover
Removal :1. Open the Rear Cover Asm.2. Release the Exit Cover (1) by pushing in the two
latches (2) at the rear of the printer.3. Remove the Exit Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 380
Exit MotorParts Reference: Exit Motor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Disconnect MCU plug P/J32.4. Remove the Front Left Cover (p. 395).5. Remove the Rear Cover Asm (p. 473).6. Remove the Controller Cover (p. 348).7. Remove the Left Cover (p. 408).8. Remove the Top Cover (p. 493).9. Remove the PCB Cover Plate (p. 467).
10. Disconnect PJ32 from the MCU.11. Remove the Rear Cover Interlock Switch (p. 475).12. Remove the Exit Asm (p. 379).13. Remove the two screws (1) and then remove the
Exit Motor (2) from the Exit Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 381
Exit Roll 1
2
3
3
1
HK
A03
9FB
Right
Left
Parts Reference: Exit Roll 1
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Rear Cover Interlock Switch (p. 475).7. Lift the tab on Exit Gear-17 (1) and remove it from
Exit Roll 1.8. Use a small screwdriver to remove the bearings (3)
from the Exit Asm.9. Remove the Exit Roll 1 from the Exit Asm.
Note: The four Exit Pinch Rolls will fall out whenthe Exit Roll 1 is removed.
10. Slide the bearings off Exit Roll 1.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 382
Exit Roll 3
1
2
3
3
HK
A03
8FB
Right
Left
Parts Reference: Exit Roll 3
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Rear Cover Interlock Switch (p. 475).7. Lift the tab on Exit Gear-17 (1) and slide Exit
Gear-17 from the Exit Roll 3 (2).8. Use a small screwdriver to remove the left and right
bearings (3) from the Exit Asm.9. Remove Exit Roll 3 from the Exit Asm.
10. Remove the left and right bearings from Exit Roll 3.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 383
Exit Static EliminatorParts Reference: Exit Static Eliminator
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Raise the left end of Exit Static Eliminator (1) up
from the left mounting position of the Exit Asm.7. Slide the right end of Exit Static Eliminator from the
right mounting position of the Exit Asm, and removethe Exit Static Eliminator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 384
Face-Up Chute
1
1
HK
A08
9FB
2
3
5
6
Parts Reference: Face Up Chute
Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the two screws (6) that hold the Face-Up
Gear Cover (5) to the Rear Cover Asm (3).3. Remove the two screws (1) that hold the Face-Up
Chute (2) to the Rear Cover Asm (3).4. Remove the Face-Up Gear Cover and the Face-Up
Chute.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 385
Fan MotorParts Reference: Fan Motor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J283 (1) from the LVPS.9. Release the harness of the Fan Motor (2) from two
clamps in the printer.10. Remove the four screws (3) that hold the Fan
Motor to the printer.11. Remove the Fan Motor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 386
Feed Asm
1
1
1
1
HK
A0Y
2FB
2
Parts Reference: Feed Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the seven screws (1) that hold the Feed
Asm (2) to the printer.12. Remove the Feed Asm from the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 387
Feed Roll Asm
HK
A0Z
0FB
1
1
2
Parts Reference: Feed Roll Asm
Removal :
1. Remove the Front Cover Asm (p. 391).
2. Remove the 550-Sheet Tray Asm (p. 325).
3. Remove the Front Left Cover (p. 395).
4. Remove the Controller Cover (p. 348).
5. Remove the Left Cover (p. 408).
6. Remove the Top Cover (p. 493).
7. Remove the Right Cover (p. 483).
8. Remove the PCB Cover Plate (p. 467).
9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).
11. Remove the Feed Asm (p. 387).
12. Disconnect P/J64 (not shown) on the Feed Roll Clutch from theFeed Asm.
13. Remove the four screws (1) that hold the Feed Roll Asm (2) tothe Feed Asm.
14. Remove the Feed Roll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 388
Feed PCBParts Reference: Feed PCB
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect the following four connectors from the
Feed PCB (1):v P/J64v P/J65v P/J66v P/J67
13. Remove the four screws (2) that hold the FeedPCB to the Feed Asm.
14. Remove the Feed PCB from the Feed Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 389
Feed Tray ConnectorParts Reference: Feed Tray Connector
Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the two screws (1) that hold the Feed Tray
Connector (2) to the Feed Asm.3. Remove the Feed Tray Connector from the Feed
Asm.4. Disconnect P/J671 (3) from the Feed Tray
Connector.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 390
Front Cover Asm
2
1
HK
A06
7FB
4
3 Parts Reference: Front Cover Asm
Removal :1. Open the Front Cover Asm (1).2. Remove the E-clip (2).3. Remove the Front Cover Spring (4) from the Front
Cover Stop (3).4. Remove the Front Cover Stop from the right cover.5. Move the Front Cover Asm to the right to remove it
from the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 391
Front Cover Interlock SwitchParts Reference: Front Cover Interlock Switch
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J284 (1) from the LVPS.9. Unclamp the harness of the Front Cover Interlock
Switch (2) from the printer.10. Remove the two screws (3) that hold the Front
Cover Interlock Switch to the printer.11. Remove the Front Cover Interlock Switch.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 392
Front Duplex Roll
4
2
HK
A0E
2FC
1
3
Parts Reference: Front Duplex Roll
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the front Duplex Roll Retaining Clip (p.
359).8. Remove the Duplex Drive Belt (p. 353).9. Remove the Duplex Gear 17/Pulley (1) from the
Front Duplex Roll (2).10. Use a small screwdriver to remove the left Duplex
Roll Bearing (3) from the left shaft of the FrontDuplex Roll.
11. Use a small screwdriver to remove the right DuplexRoll Bearing (4) from the right shaft of the FrontDuplex Roll.
Continued on p. 394.
Chapter 5. Removals and Replacements 393
Parts Reference: Front Duplex Roll
Continued from p. 393.12. Move the Front Duplex Roll (2) to the upper bearing
of the Duplex Asm.13. Move the Front Duplex Roll to the left and remove
the right shaft of the Front Duplex Roll from theDuplex Asm.
14. Lift the right shaft of the Front Duplex Roll andremove the Front Duplex Roll from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 394
Front Left CoverParts Reference: Front Left Cover
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the three screws (1) that hold the Front Left
Cover (2) to the printer.4. Use a screwdriver to release the upper left hook of
the Front Left Cover.5. Remove the Front Left Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 395
Full Stack ActuatorParts Reference: Full Stack Actuator
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Exit Static Eliminator (p. 384).7. Raise the left shaft of Full Stack Actuator (1) to
remove it from the left bearing of the Exit Asm.8. Slide the right shaft of the Full Stack Actuator from
the right bearing of the Exit Asm, and remove theFull Stack Actuator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 396
Full Stack Photo SensorParts Reference: Full Stack Photo Sensor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Remove the Exit Static Eliminator (p. 384).7. Remove the Full Stack Actuator (p. 396).8. Disconnect P/J311 (1) from the Full Stack Photo Sensor
(2).9. Release the hooks that hold the Full Stack Photo Sensor
to the Exit Asm and remove the Full Stack Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 397
Fuser Asm
2
1
HK
A03
5FA
Right
Left
Parts Reference: Fuser Asm 230 v, Fuser Asm 120 v
Removal :
CAUTION:
<2-43> High temperature; switch off the printer and allow at least 30 minutesfor parts in this area to cool before handling.
hcsf
0243
1. Open the Rear Cover Asm.2. Remove the two screws (1) that hold the Fuser Asm
(2) to the printer.3. Remove the Fuser Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 398
Fuser StopParts Reference: None
Removal :1. Open the Rear Cover Asm (2).2. Pull the Fuser Stops (1) from the left and right holes
of the Face-Up Chute.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 399
Gear Drive AsmParts Reference: Gear Drive Asm
Removal :
1. Remove the Front Cover Asm (p. 391).
2. Remove the 550-Sheet Tray Asm (p. 325).
3. Remove the Front Left Cover (p. 395).
4. Open the Rear Cover Asm (p. 473).
5. Remove the Fuser Asm (p. 398).
6. Remove the Controller Cover (p. 348).
7. Remove the Controller PCB. (p. 349).
8. Remove the Left Cover (p. 408).
9. Remove the Top Cover (p. 493).
10. Remove the Aux Tray Asm (p. 342).
11. Remove the Aux Drive Gear Shaft and Aux Drive Gear (p. 327).
12. Remove the Toner Cartridge.
13. Remove the Paper Handling Asm (p. 462).
14. Remove the BTR Support Asm (p. 347).
15. Remove the PCB Cover Plate (p. 467).
16. Remove the Left Handle Plate (p. 409).
17. Remove the MCU PCB (p. 415).
18. Remove the Main Motor (p. 413)
19. Remove the LVPS (p. 412).
20. Remove the four screws (1) that hold the Gear Drive Asm (2) tothe printer.
21. Remove the Gear Drive Asm.
Replacement: Reverse the removal procedure.Note: The letter ″D″ is written near the four holes where the Gear DriveAsm screws are mounted.
Chapter 5. Removals and Replacements 400
Harness (J27, J11, J262 - J271)Parts Reference: Harness (J27, J11, J262-J271)
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm (p. 473).5. Remove the Fuser Asm (p. 398).6. Remove the Controller Cover (p. 348).7. Remove the Left Cover (p. 408).8. Remove the Top Cover (p. 493).9. Remove the Aux Tray Asm (p. 342).
10. Remove the Aux Drive Gear Shaft (p. 327).11. Remove the Aux Drive Gear (p. 327).12. Remove the Toner Cartridge.13. Remove the Paper Handling Asm (p. 462).14. Remove the BTR Support Asm (p. 347).15. Remove the PCB Cover Plate (p. 467).16. Remove the Left Handle Plate (p. 409).17. Remove the MCU PCB (p. 415).18. Remove the Main Motor (p. 413)19. Remove the LVPS (p. 412).20. Remove the Gear Drive Asm (p. 400).
Continued on p. 402.
Chapter 5. Removals and Replacements 401
Parts Reference: Harness (J27, J11, J262-J271),Harness (J27, J11, J262-J271)
Continued from p. 401.21. Disconnect P/J261 on the HVPS.22. Remove the one screw that hold the HVPS
Housing and the HVPS to the printer.23. Remove the HVPS Housing with the HVPS.24. Disconnect P/J27 from the MCU PCB.25. Disconnect P/J11 from the LVPS.26. Pull the Harness (J27, J11, J262 - J271) (1) from
the left hole in the printer.27. Remove the two screws (2) that hold the Harness
(J27, J11, J262 - J271) to the printer.28. Remove the Harness (J27, J11, J262 - J271).
Replacement: Reverse the removal procedure.Note: Do not install Harness (J27, J11, J262 - J271) inthe reversed position. Verify correct installation using theFuser.
Chapter 5. Removals and Replacements 402
Harness (J34-P341)Parts Reference: Harness (J34 - P341):
Removal :1. Remove the Front Cover Asm (p. 391).
2. Remove the 550-Sheet Tray Asm (p. 325).
3. Remove the Front Left Cover (p. 395).
4. Open the Rear Cover Asm (p. 473).
5. Remove the Fuser Asm (p. 398).
6. Remove the Controller Cover (p. 348).
7. Remove the Left Cover (p. 408).
8. Remove the Top Cover (p. 493).
9. Remove the Aux Tray Asm (p. 342).
10. Remove the Aux Drive Gear Shaft (p. 327).
11. Remove the Aux Drive Gear (p. 327).
12. Remove the Toner Cartridge.
13. Remove the Paper Handling Asm (p. 462).
14. Remove the BTR Support Asm (p. 347).
15. Remove the PCB Cover Plate (p. 467).
16. Remove the Left Handle Plate (p. 409).
17. Remove the MCU PCB (p. 415).
18. Remove the Main Motor (p. 413)
19. Remove the LVPS (p. 412).
20. Remove the Gear Drive Asm (p. 400).
21. Disconnect P/J34 (1) from the MCU PCB.
22. Remove the two screws (2) that hold the Harness (J34-P341) (3)to the printer.
23. Slide the Harness (J34-P341) from the hole in the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 403
Harness (J35 - J351)Parts Reference: Harness (J35 - J351):
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J35 (1) from the MCU PCB.9. Unclamp the Harness (J35 - J351) (2) from the
printer.10. Remove the two screws (3) that hold the Harness
(J35 - J351) to the printer.11. Slide the Harness (J35 - J351) from the hole in the
printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 404
Harness (J51 - J511)Parts Reference: Harness (J51 - J511)
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove the Paper Size Housing (p. 464).
10. Disconnect P/J51 (1) of Harness (J51 - J511) (2)from the Paper Sizing PCB.
11. Remove the two screws (3) that hold Harness (J51- J511) to the Paper Size Housing.
12. Slide off the harness of Harness (J51 - J511) fromthe Paper Size Housing, and remove the Harness(J51 - J511).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 405
HVPSParts Reference: HVPS
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the Bias Transfer Roll (p. 346).
10. Remove the BTR Support Asm (p. 347).11. Disconnect P/J261 (1) from the HVPS.12. Remove the one screw (2) that holds the HVPS (3)
and HVPS Housing (4) to the printer.13. Remove the HVPS Housing and the HVPS from the
printer.14. Release the hooks that hold the HVPS to the HVPS
Housing and remove the HVPS.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 406
Interface PCBParts Reference: Interface PCB
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Top Cover (p. 493).5. Disconnect the following connectors from the
Interface PCB (1).v P/J41v P/J42v P/J43v P/J44v P/J45v P/J231
6. Remove the three screws (2) that hold the InterfacePCB to the printer.
7. Remove the Interface PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 407
Left CoverParts Reference: Left Cover
Removal :1. Remove the Controller Cover (p. 348).2. Remove the two screws (1) that hold the Left Cover
(2) to the printer.3. Remove the Left Cover.
Replacement: Reverse the removal procedure. Makesure the Left Cover properly fits with the Top Cover andthe Front Left Cover.
Chapter 5. Removals and Replacements 408
Left Handle PlateParts Reference: None
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the four screws (1) that hold the Left
Handle Plate (2) to the printer.7. Remove the Left Handle Plate.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 409
Left Registration Roll Spring
1
HK
A06
9FC
Parts Reference: Left Registration Roll Spring
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Use a small screwdriver to unhook the Left
Registration Roll Spring (1) from the Left Metal RollBearing.
10. Use a small screwdriver to unhook the LeftRegistration Roll Spring from the UpperRegistration Chute.
11. Slide the Left Registration Roll Springs down.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 410
Lift Control Photo Sensor
1
HK
A0Z
4FB
Parts Reference: None
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect P/J661 from the Lift Control Photo
Sensor (1).13. Release the hooks that hold the Lift Control Photo
Sensor to the Feed Asm, and remove the LiftControl Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 411
LVPS
1
HK
A06
1FB
2
2
2
28511
283 282
281
284
Parts Reference: LVPS 120V, LVPS 230V
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Remove the Left Handle Plate (p. 409).5. Remove the Main Power Switch (p. 414).6. Disconnect the following connectors from the LVPS
(1):v P/J282v P/J283v P/J284v P/J285v P/J11
7. Remove the four screws (2) that hold the LVPS tothe printer.
8. Remove the LVPS.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 412
Main Motor
3
3
2
3
1
HK
A05
0FB
Parts Reference: Main Motor
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect P/J29 (1) from the MCU PCB.5. Remove the four screws (3) that hold the Main Motor
(2) to the printer.6. Remove the Main Motor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 413
Main Power Switch
1
1
HK
A07
7FB
Parts Reference: Main Power Switch
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Remove the Left Handle Plate (p. 409).5. Disconnect the harness attached to the LVPS from
the Main Power Switch (1).6. Push the Main Power Switch so that it comes out of
the front of the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 414
MCU PCBParts Reference: MCU PCB
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the PCB Cover Plate (p. 467).4. Disconnect the following connectors from the MCU
PCB (1):v P/J21v P/J23v P/J25v P/J26v P/J27v P/J28v P/J29v P/J30v P/J31v P/J32v P/J33v P/J34v P/J35
5. Remove the four screws (2) that hold the MCU PCBto the printer.
6. Remove the MCU PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 415
Metal Registration Roll GearParts Reference: Metal Registration Roll Gear
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Release the E-ring (1) that holds the Metal
Registration Roll Gear (2) to the Paper HandlingAsm.
10. Slide the Metal Registration Roll Gear off the PaperHandling Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 416
Middle Duplex RollParts Reference: Middle Duplex Roll
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Top Cover (p. 360).6. Remove the Duplex Motor (p. 355).7. Remove the middle Duplex Roll Retaining Clip (p.
359).8. Remove the Duplex Drive Belt (p. 353).9. Remove the Duplex Gear 17/Pulley (1) from the
Middle Duplex Roll (2).10. Remove the Duplex Gear 17/39 (3) from the shaft
of the Duplex Asm.11. Remove the Duplex Gear 18 (4) from the shaft of
the Duplex Asm.12. Use a small screwdriver to remove the left Duplex
Roll Bearing (5) from the left shaft of the MiddleDuplex Roll.
13. Use a small screwdriver to remove the right DuplexRoll Bearing (6) from the right shaft of the MiddleDuplex Roll.
Continued on p. 418.
Chapter 5. Removals and Replacements 417
Parts Reference: Middle Duplex Roll
Continued from p. 417.14. Move the Middle Duplex Roll (2) to the upper
bearing of the Duplex Asm.15. Move the Middle Duplex Roll to the left and then
remove the right shaft of the Middle Duplex Rollfrom the Duplex Asm.
16. Lift the right side of the Middle Duplex Roll andthen remove the Middle Duplex Roll from theDuplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 418
No Paper Actuator
HK
A0Z
3FB
1
2
Right
Left
Parts Reference: No Paper Actuator
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Unhook the left and right shafts of the No Paper
Actuator (1) from the left and right No PaperActuator Supports (2), and remove the No PaperActuator from the Feed Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 419
Offset Asm
1
HK
A0G
1FA
Parts Reference: Offset Asm
Removal :1. Open the Rear Cover.2. Release the two hooks on the back of the Offset
Asm (1) and remove the Offset Asm.3. If you do not re-install the Offset Asm, install the
Cover Option on the Cover Asm Top.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 420
Offset Direction Solenoid
1
2
3
HK
A0H
2FA
Parts Reference: Offset Direction Solenoid
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Disconnect connector P/J228 (1).9. Remove the two screws (3) that hold the Offset
Direction Solenoid (2) to the Offset Inner Asm.10. Unhook the harness of the Offset Direction
Solenoid from the Offset Inner Asm and remove theOffset Direction Solenoid.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 421
Offset Direction Home Sensor
1
2 HK
A0I
4FB
Parts Reference: Offset Direction Home Sensor
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the Offset Mechanism Asm (432).9. Release the hooks that hold the Offset Direction
Home Sensor (1) to the Offset Asm (2).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 422
Offset Drive Motor
1
1
2
3
HK
A0H
0FA
Right
Left
Parts Reference: Offset Drive Motor
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the two screws (1) that hold the Offset
Drive Motor (2) to the Offset Inner Asm.9. Remove the Offset Drive Motor from the Offset
Inner Asm.10. Disconnect connector P/J210 (3).
Replacement: Reverse the removal procedure.Note: The Offset Drive Motor must be mounted with itsconnector facing the front.
Chapter 5. Removals and Replacements 423
Offset Exit Bin
1 HK
A0G
4FA
2
Parts Reference: Offset Exit Bin
Removal :1. Remove the Offset Exit Asm (p. 425).2. Remove the right shaft of the Offset Exit Bin (1) from
the right hole in the Offset Top Cover (2).3. Remove the left shaft of the Offset Exit Bin from the
left hole in the Offset Top Cover and remove theOffset Exit Bin.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 424
Offset Exit Bin Asm
1
2
HK
A0G
2FA
Parts Reference: Offset Exit Asm
Removal :1. Open the Offset Exit Asm.2. Remove the right side of the Offset Exit Asm (1)
from the right hole in the Offset Top Cover (2).3. Remove the left side of the Offset Exit Asm from the
left hole in the Offset Top Cover, and remove theOffset Exit Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 425
Offset Exit Photo Sensor
1
2
HK
A0H
3FC
Parts Reference: Offset Exit Bin Sensor
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Release the hooks that hold the Offset Exit Photo
Sensor (1) to the Offset Inner Asm.9. Disconnect connector P/J227 (2) from the Offset Exit
Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 426
Offset Full Stack Actuator
1
HK
A0H
4FB
Parts Reference: Offset Full Stack Actuator
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the left shaft of the Offset Full Stack
Actuator (1) from the Offset Inner Asm.9. Release the right shaft of the Offset Full Stack
Actuator from the Offset Inner Asm, and remove theOffset Full Stack Actuator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 427
Offset Full Stack Photo Sensor
12
HK
A0H
5FA
Right
Left
Parts Reference: Offset Full Stack Photo Sensor
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the Offset PCB (p. 434).9. Disconnect connector P/J225 (1) from the Offset
Full Stack Photo Sensor (2).10. Release the hooks that hold the Offset Full Stack
Photo Sensor to the Offset Inner Asm and removethe Offset Full Stack Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 428
Offset Inner Asm
32
1
2
HK
A0G
8FB
Bottom
Top
Parts Reference: Offset Inner Asm
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover (1).6. Remove the Offset Lower Cover (p. 431).7. Remove the five screws (2) that hold the Offset Inner
Asm (3) to the Offset Asm.8. Remove the Offset Inner Asm from the Offset Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 429
Offset Inner Chute Cover
1
1
2
HK
A0I
0FB
Bottom
Top
Parts Reference: Offset Inner Chute Cover
Removal :1. Remove the four screws (1) that hold the Offset
Inner Chute Cover (2) to Offset Inner Asm.2. Remove the Offset Inner Chute Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 430
Offset Lower Cover
11
2
3
HK
A0I
1FB
Bottom
Top
Parts Reference: Offset Lower Cover
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the six screws (1) that hold the Offset
Lower Cover (2) to the Offset Inner Asm.7. Remove the Offset Lower Cover from the Offset
Inner Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 431
Offset Mechanism Asm
1
2 3
HK
A0I
2FC
Parts Reference: Offset Asm
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Unhook the Offset Lever (1) from the Offset Inner
Asm.9. Remove the two screws (2) and then remove the
Offset Asm (3) from the Offset Inner Asm.10. Disconnect connector P/J226 from the Offset
Direction Home Sensor.11. Disconnect connector P/J210 of the Offset Motor.12. Unclamp the harness of the Offset Motor at two
places from the Offset Inner Asm.13. Remove the Offset Asm from the Offset Inner Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 432
Offset Paper Weight
1
HK
A0G
5FB
Parts Reference: Offset Paper Weight
Removal :1. Squeeze the left and right brackets of the Offset
Paper Weight (1) and remove it from the Offset Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 433
Offset PCB
1
2
HK
A0G
9FA
Right
Left
Parts Reference: Offset PCB
Removal :1. Remove the Offset Paper Weight (p. 433).2. Remove the Offset Exit Asm (p. 425).3. Remove the Offset Exit Bin (p. 424).4. Remove the Offset Tray Spring (p. 436).5. Open the Offset Rear Cover.6. Remove the Offset Lower Cover (p. 431).7. Remove the Offset Inner Asm (p. 429).8. Remove the one screw (1) that holds the Offset
PCB (2) to the Offset Inner Asm.9. Disconnect the following connectors from the Offset
PCB.v P/J223v P/J210v P/J224v P/J209
10. Remove the Offset PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 434
Offset Rear Cover
1 HK
A0G
6FBRight
Left
Parts Reference: Offset Rear Cover
Removal :1. Open the Offset Rear Cover (1).2. Use a small screwdriver to remove the right bracket
of the Offset Rear Cover from the right hole in theOffset Top Cover.
3. Slide the left shaft of the Offset Rear Cover from theleft hole in the Offset Top Cover, and remove theOffset Rear Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 435
Offset Tray Spring
1
HK
A0G
3FB
2 Parts Reference: Offset Tray Spring
Removal :1. Remove the Offset Exit Asm (p. 425).2. Remove the Offset Exit Bin (p. 424).3. Turn the right Offset Tray Spring (1) to the left
(counter-clockwise), remove it from the hook of theOffset Asm.
4. Turn the left Offset Tray Spring (2) to the left(counter-clockwise), remove it from the hook of theOffset Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 436
Operator Panel
2
1 1
3 HK
A08
3FA
Parts Reference: Operator Panel
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the Top Cover (p. 493).6. Remove the four screws (1) that hold the Operator
Panel (2) to the Top Cover.7. Remove the Operator Panel from the Top Cover.8. Disconnect the Harness (J4-Operator Panel) (3) from
the Operator Panel.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 437
Option Chute SpringParts Reference: None
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the Option Feed Roll Asm (p. 441).8. Unhook the Option Chute Spring from the Option
Feed Roll Asm (2), and remove the Option ChuteSpring.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 438
Option Feed AsmParts Reference: Option Feed Asm
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the six screws (1) and remove the Option
Feed Asm (2) from the Option 550-Sheet Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 439
Option Feed PCBParts Reference: Option Feed PCB
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect the following connectors on the Option
Feed PCB (1) from the Option Feed Asm.:v P/J64v P/J65v P/J66v P/J67
8. Remove the four screws (2) and then remove theOption Feed PCB from the Option Feed Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 440
Option Feed Roll AsmParts Reference: Option Pick Roll Asm
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J641 on the Option Feed
Roll Clutch from the Option Feed Asm.8. Remove the four screws (1) that hold the Option
Feed Roll Asm (2) to the Option Feed Asm.9. Remove the Option Feed Roll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 441
Option Gear BracketParts Reference: Option Gear Bracket
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the five screws (1) that hold the Option
Gear Bracket (2) to the Option Paper Drawer.3. Remove the Option Gear Bracket from the Option
Paper Drawer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 442
Option Harness (J52-J521)Parts Reference: Option Harness (J52 - J521)
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the two screws (1) that hold the Option
Harness (J52-J521) (2) to the Option Paper Drawer.4. Insert the Option Harness (J52-J521) into the hole in
the Option Paper Drawer.
Continued on p. 444.
Chapter 5. Removals and Replacements 443
Parts Reference: Option Harness (J52 - J521)
Continued from p. 443.5. Use a small screwdriver to push one boss that holds
the Option Paper Sizing Sensor Asm (3) to theOption Paper Drawer to release the boss from thehole.
6. Slide the Option Paper Sizing Sensor Asm andOption Harness (J52-J521) (2) to the rear from theOption Paper Drawer.
7. Remove the Option Paper Sizing Sensor Cover (p.451).
8. Disconnect connector P/J52 (4) of the OptionHarness (J52-J521).
9. Remove the Option Paper Sizing Sensor Asm fromthe Option Paper Drawer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 444
Option Harness (J53-531)Parts Reference: Option Harness (J53 - J531)
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the Option Paper Size Front Cover (p. 451).6. Disconnect connector P/J53 (1) from the Option
Paper Size PCB.7. Remove the two screws (2) that hold the Option
Harness (J53-531) (3) to the Option Paper SizeSensor Asm.
8. Remove the Option Harness (J53-531) from theOption Paper Size Sensor Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 445
Option Left CoverParts Reference: Option Left Cover
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the four screws (1) that hold the Option Left
Cover (2) to the Option Paper Drawer.3. Gently lift the left side of Option Paper Drawer and
then remove the Option Left Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 446
Option Lift Control Photo Sensor
1
HK
A0B
3FD
2
Parts Reference: None
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J662 (1) from the Option Lift
Control Photo Sensor (2).8. Release the hooks and remove the Option Lift
Control Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 447
Option No Paper ActuatorParts Reference: Option No Paper Actuator
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Unhook the left and right shafts of Option No Paper
Actuator (1) from the left and right Option No PaperActuator Supports (2), and remove the Option NoPaper Actuator from the Option Feed Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 448
Option Paper DrawerParts Reference: Option Paper Drawer
Removal :1. Remove the three screws (1) that hold the Option
Paper Drawer (2) to the printer.2. Lift the printer off of the drawer.
CAUTION:
<2-41> The printer weighs approximately 28 kg (62 lb). Use two personsto carry the printer. Use appropriate lifting precautions.
hcsf
0241
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 449
Option Paper Low Photo Sensor
1
HK
A0B
3FC
2
Parts Reference: Option Paper Low Photo Sensor
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Disconnect connector P/J661 (1) from the Option
Paper Low Photo Sensor (2).8. Release the hooks and remove the Option Paper
Low Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 450
Option Paper Size Front Cover
1
1
HK
A0C
2FB
2
3
4
Front
Rear
Parts Reference: Option Paper Size Front Cover
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the four screws (1) that hold the Option
Paper Size Front Cover (2) to the Option Paper SizeSensor Asm (3).
6. Release two hooks (4) and remove the Option PaperSize Front Cover from the Option Paper Size SensorAsm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 451
Option Paper Size PCBParts Reference: Option Paper Size PCB
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the Option Harness (J52-J521) (p. 443).4. Remove the Option Paper Size Sensor Asm (p. 453).5. Remove the Option Paper Size Front Cover (p. 451).6. Disconnect connector P/J53 from the Option Paper
Size PCB (1).7. Remove the two screws (2) and remove the Option
Paper Size PCB from the Option Paper Size SensorAsm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 452
Option Paper Size Sensor Asm
2
HK
A0A
4FA
3
1 Parts Reference: Option Paper Size Sensor Asm
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Left Cover (p. 446).3. Remove the two screws that hold the Option
Harness (J52-J521) (2) to the Option Paper Drawer.4. Insert the Option Harness (J52-J521) into the hole in
the Option Paper Drawer.5. Use a small screwdriver to push the one boss (4)
through the hole in the Option paper drawer.6. Remove the Option Paper Size Sensor Asm (3) and
the Option Harness (J52-J521) (2) from the OptionPaper Drawer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 453
Option Pick Clutch - ElectricParts Reference: Option Pick Clutch - Electric
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the four screws (1) and then remove the
Option Gear Bracket (2) from the Option Feed Asm.8. Slide the Option Gear 3 (3) from the shaft of the
Option Feed Asm.9. Slide the Option Gear 2 (4) from the shaft of the
Option Feed Asm.
Continued on p. 455.
Chapter 5. Removals and Replacements 454
Parts Reference: Option Pick Clutch - Electric
Continued from p. 454.10. Disconnect connector P/J65 (5).11. Release the E-ring (6) and slide the Option Pick
Clutch - Electric (7) from the shaft of Option PickRoll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 455
Option Pick RollParts Reference: Option Pick Roll
Removal :1. Slide the Option 550-Sheet Tray Asm from the
Option Paper Drawer.2. Open the Option Feed Position Plate (1).3. Unhook the latches on the Option Pick Rolls (2), and
slide them off the shafts of the Option Pick Roll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 456
Option Pick Roll AsmParts Reference: Option Pick Roll Asm
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the Option Top Front Plate (p. 461).6. Remove the Option Feed Asm (p. 439).7. Remove the Option Pick Clutch - Electric (p. 454).8. Release the E-ring (1).9. Slide the bearing (3) off the left shaft of the Option
Pick Roll Asm (2).
Continued on p. 458.
Chapter 5. Removals and Replacements 457
Parts Reference: Option Pick Roll Asm
Continued from p. 457.10. Open the Option Feed Position Plate (4).11. Slide the Option Pick Roll Asm (2) to the right to
remove it from the Option Feed Asm. Be careful notto lose the spring (5).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 458
Option Right CoverParts Reference: Option Right Cover
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the four screws (1) that hold the Option
Right Cover (2) to the Option Paper Drawer.3. Raise the right side of Option Paper Drawer slightly.
Then remove the Option Right Cover.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 459
Option SocketParts Reference: Option Socket
Removal :1. Remove the Option 550-Sheet Tray Asm.2. Remove the two screws (1) and then remove the
Option Socket (2) from the Option Feed Asm.3. Disconnect connector P/J71 (3) from the Option
Socket.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 460
Option Top Front PlateParts Reference: Option Top Front Plate
Removal :1. Remove the Option Paper Drawer (p. 449).2. Remove the Option Gear Bracket (p. 442).3. Remove the Option Right Cover (p. 459).4. Remove the Option Left Cover (p. 446).5. Remove the one screw (1) that holds the Option Top
Front Plate (2) to the Option Paper Drawer.6. Remove the Option Top Front Plate from the Option
Paper Drawer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 461
Paper Handling AsmParts Reference: Paper Handling Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Disconnect P/J42 and P/J43 (1) from the Interface
PCB.9. Release two clamps from the harness of the Paper
Handling Asm.10. Remove the five screws (2) that hold the Paper
Handling Asm (3) to the printer.11. Lift the right side of the Paper Handling Asm and
then slide it to the right to remove.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 462
Paper Low Photo Sensor
HK
A0Z
4FC
Parts Reference: Paper Low Photo Sensor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Disconnect P/J662 from the Paper Low Photo
Sensor (2).13. Release the hooks that hold the Paper Low Photo
Sensor to the Feed Asm, and remove the PaperLow Photo Sensor.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 463
Paper Size Housing
1
1
HK
A05
4FB
2
3
4
Front
Rear
Parts Reference: Paper Size Housing
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove four screws (1) that hold the Paper Size
Housing (2) to the Paper Size Housing Asm (3).10. Release two hooks (4) and remove the Paper Size
Housing from the Paper Size Housing Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 464
Paper Size Housing Asm
1
HK
A05
3FA
2
3
Parts Reference: Paper Size Sensor Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Disconnect P/J33 (1) from the MCU PCB.9. Release three clamps that hold Harness P/J33 -
P/J331 to the printer frame.10. Use a small screwdriver to push a peg (3) and slide
the Paper Size Housing Asm to the rear.11. Slide the harness of the Paper Size Housing Asm
from the hole in the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 465
Paper Sizing PCBParts Reference: Paper Size PCB
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the PCB Cover Plate (p. 467).7. Remove the Left Handle Plate (p. 409).8. Remove the Paper Size Housing Asm (p. 465).9. Remove the Paper Size Housing (p. 464).
10. Remove the two screws (1) that hold the Paper SizingPCB (2) to the Paper Size Housing.
11. Remove the Paper Sizing PCB from the Paper SizeHousing.
12. Disconnect P/J51 from the Paper Sizing PCB.13. Disconnect P/J331 from the Paper Sizing PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 466
PCB Cover PlateParts Reference: None
Removal :1. Remove the Controller Cover (p. 348).2. Remove the Left Cover (p. 408).3. Remove the six screws (1) that hold the PCB Cover
Plate (2) to the printer.4. Remove the PCB Cover Plate.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 467
Pick Clutch - Electric
1
3
HK
A0Z
9FB
2
Right
Left5
4
Parts Reference: Pick Clutch - Electric
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Remove the one screw that holds clamp (5) to the Feed
Bracket (2), and remove the clamp.13. Remove the three screws (1) that hold the Feed Bracket
to the Feed Asm, and remove the Feed Bracket from theFeed Asm.
14. Slide the Feed Gears (3, 4) off the shafts of the FeedAsm.
Continued on p. 469.
Chapter 5. Removals and Replacements 468
HK
A0Y
0FA
Right
Left
67
8
Parts Reference: Pick Clutch - Electric
Continued from p. 468.15. Remove the E-ring (6) and then slide the Pick Clutch -
Electric (7) off the shaft of the Pick Roll Asm.16. Disconnect P/J65 (8) from the Feed PCB.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 469
Pick RollParts Reference: Pick Roll
Removal :1. Remove the 550-Sheet Tray Asm.2. Open the Feed Position Plate (1).3. Unhook the latch on the front Pick Roll (2) and slide
it off the front shaft of the Pick Roll Asm.4. Unhook the latch on the rear Pick Roll (2) and slide
it off the rear shaft of the Pick Roll Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 470
Pick Roll Asm
1
HK
A0Z
5FB
2
3
Parts Reference: Pick Roll Asm
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the Right Cover (p. 483).8. Remove the PCB Cover Plate (p. 467).9. Remove the Left Handle Plate (p. 409).
10. Remove the LVPS (p. 412).11. Remove the Feed Asm (p. 387).12. Remove the Pick Clutch - Electric (p. 468).13. Release the E-ring (1), and then slide the bearing
(2) from the shaft of the Pick Roll Asm (3).
Continued on p. 472.
Chapter 5. Removals and Replacements 471
35
HK
A0Z
6FC
4
Right
Top
Left
Parts Reference: Pick Roll Asm
Continued from p. 471.14. Open the Feed Position Plate (4) from the Feed
Asm.15. Slide the shaft of the Pick Roll Asm (3) off of the
bearing hole, and remove it from the Feed Asm. Becareful not to lose the spring (5).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 472
Rear Cover AsmParts Reference: Rear Cover Asm (With Face-Up Bin),Rear Cover Asm (Without Face-Up Bin)
Removal :1. Open the Rear Cover Asm (1).2. Slide the lead edge of the Rear Cover Stop (not
shown) from the Rear Cover Asm and remove thestrap.
3. Pull the Rear Cover Pivot Stop (2) and slide theRear Cover Asm off the pivot shafts of the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 473
Rear Cover Interlock SwitchParts Reference: Rear Cover Interlock Switch
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Controller Cover (p. 348).6. Remove the Left Cover (p. 408).7. Remove the Top Cover (p. 493).8. Remove the PCB Cover Plate (p. 467).9. Remove the Rear Cover Interlock Switch (p. 475).
10. Remove the Exit Asm (p. 379).11. Disconnect P/J30 (1) from the MCU PCB.12. Unclamp the harness of the Rear Cover Interlock
Switch (2) from the printer.13. Remove the two screws (3) that hold the Rear
Cover Interlock Switch to the printer.14. Slide the harness of the rear cover switch from the
hole in the printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 474
Rear Cover Interlock SwitchParts Reference: Rear Cover Interlock Switch
Removal :1. Remove the Rear Cover Asm (p. 473).2. Remove the three screws (1) that hold the Rear
Cover Interlock Switch (2) to the printer.3. Remove the Rear Cover Interlock Switch.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 475
Rear Cover StopParts Reference: Rear Cover Stop
Removal :1. Open the Rear Cover Asm.2. Remove the one screw (1) that holds the Rear Cover
Stop (2) to the printer.3. Remove the Rear Cover Stop from the Rear Cover
Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 476
Rear Duplex Roll
1 5
HK
A0D
6FC
6
4 3
2
Parts Reference: Duplex Roll
Removal :1. Remove the Duplex Asm (p. 350).2. Remove the Duplex Bottom Cover (p. 351).3. Remove the Duplex Motor Cover (p. 356).4. Remove the Duplex Connector Asm (p. 352).5. Remove the Duplex Motor (p. 355).6. Remove the Duplex Upper Guide (p. 361).7. Remove the Duplex Roll Retaining Clip (p. 359).8. Remove the Duplex Gear 17/Pulley (1) from the
Duplex Roll (2).9. Remove the Duplex Gear 17/39 (3) from the shaft
of the Duplex Asm.10. Remove the Duplex Gear 18 (4) from the shaft of
the Duplex Asm.11. Use a screwdriver to remove the left Duplex Roll
Bearing (5).12. Use a screwdriver to remove the right Duplex Roll
Bearing (6).13. Move the the Rear Duplex Roll to the front bearing
of the Duplex Asm.
Continued on p. 478.
Chapter 5. Removals and Replacements 477
Parts Reference: Duplex Roll
Continued from p. 477.14. Slide the Rear Duplex Roll to the left and remove
the right shaft of the Rear Duplex Roll from theDuplex Asm.
15. Lift the right side of the Rear Duplex Roll and thenremove it from the Duplex Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 478
Registration Actuator
HK
A02
4FA
2
3
1
Parts Reference: Registration Actuator
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute (3).
10. Release the right hook of the Registration Actuator Spring (1)from the Paper Handling Asm.
11. Move the lever of the Registration Actuator (2) to the left torelease the right shaft of Registration Actuator.
12. Remove the Registration Actuator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 479
Registration Actuator Spring
HK
A02
4FA
2
3
1
Parts Reference: Registration Actuator Spring
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute (3).
10. Release the right hook of the Registration Actuator Spring (1)from the Paper Handling Asm.
11. Hold the operating lever of the Registration Actuator (2) andmove it to the left to remove the right shaft of theRegistration Actuator.
12. Remove the Registration Actuator Spring from the shaft ofthe Registration Actuator.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 480
Registration Clutch - Electric
HK
A02
7FC
2
1
3
Right
Left
Parts Reference: Registration Clutch - Electric
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Disconnect P/J433 (1) from the Registration Clutch
- Electric (2).10. Release the E-ring (3) and slide the Registration
Clutch - Electric from the Paper Handling Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 481
Registration SensorParts Reference: Registration Sensor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Open the Front Registration Chute and the Toner
Sensor Bracket from the Paper Handling Asm.10. Remove the Registration Actuator (p. 479)11. Disconnect P/J432 from the Registration Sensor.12. Release the hooks that hold the Registration
Sensor (1), and remove the Registration Sensorfrom the rear side of the Paper Handling Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 482
Right CoverParts Reference: Right Cover
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the Top Cover (p. 493).6. Remove the four screws (1) that hold the Right
Cover (2) to the printer.7. Release the two hooks at the top of the Right Cover
from the holes in the printer.8. Release the two hooks at the bottom of the Right
Cover from the holes in the printer.
Replacement: Reverse the removal procedure. Makesure the Right Cover properly fits with the Top Cover.
Chapter 5. Removals and Replacements 483
Right Registration Roll Spring
1
HK
A06
9FD
Parts Reference: Right Registration Roll Spring
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Use a small screwdriver to unhook the Right
Registration Roll Spring (1) from the Right MetalRoll Bearing.
10. Use a small screwdriver to unhook the RightRegistration Roll Spring from the UpperRegistration Chute.
11. Slide the Right Registration Roll Springs down.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 484
ROS Asm (Laser)Parts Reference: ROS Asm (Laser)
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Rear Cover Asm (p. 473).5. Remove the Top Cover (p. 493).6. Disconnect P/J223 from the ROS Asm (Laser) (1).7. Disconnect P/J213 from the ROS Asm (Laser).8. Disconnect P/J212 from the ROS Asm (Laser).9. Remove the four screws (2) that hold the ROS Asm
(Laser) to the printer.10. Slightly raise the ROS Asm (Laser) and disconnect
P/J211 from the bottom.11. Remove the ROS Asm (Laser).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 485
Rubber Registration RollParts Reference: Rubber Registration Roll
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Remove the Left Registration Roll Spring (p. 410).
10. Remove the Right Registration Roll Spring (p. 484).11. Remove the Metal Registration Roll Gear (p. 416).12. Remove the Rubber Registration Roll Gear (p.
489).13. Remove the Registration Clutch - Electric (p. 481).14. Release the left E-ring (1) that holds the Metal
Registration Roll to the Paper Handling Asm.15. Unhook the Chute Torsion Spring from the notch of
Front Registration Chute.16. Move the Chute Torsion Spring to the left from the
Paper Handling Asm, avoiding the boss of RightMetal Roll Bearing (3).
Continued on p. 487.
Chapter 5. Removals and Replacements 486
Parts Reference: Rubber Registration Roll
Continued from p. 486.17. Closing the Front Registration Chute and Rear
Registration Chute, align the boss of Right MetalRoll Bearing with the right slit, and slide the RightMetal Roll Bearing from the Paper Handling Asm.
18. Closing the Front Registration Chute and RearRegistration Chute, align the boss of Left Metal RollBearing with the left slit, and slide the Left MetalRoll Bearing (2) from the Paper Handling Asm.
19. Slide upward the right shaft of Metal RegistrationRoll from the right bearing of Paper Handling Asm.
20. Slide diagonally and to the right the MetalRegistration Roll, the Front Registration Chute, andthe Rear Registration Chute from the PaperHandling Asm.
Continued on p. 488.
Chapter 5. Removals and Replacements 487
Parts Reference: Rubber Registration Roll
Continued from p. 487.21. Remove the Right Rubber Roll Bearing (4) and the
Left Rubber Roll Bearing (6).22. Move the Rubber Registration Roll (5) to the right
and remove the left shaft of Rubber RegistrationRoll from the Paper Handling Asm.
23. Remove the right shaft of the Rubber RegistrationRoll from the Paper Handling Asm, and remove theRubber Registration Roll.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 488
Rubber Registration Roll GearParts Reference: Rubber Registration Roll Gear
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Aux Tray Asm (p. 342).5. Remove the Aux Drive Gear Shaft (p. 327).6. Remove the Aux Drive Gear (p. 327).7. Remove the Toner Cartridge.8. Remove the Paper Handling Asm (p. 462).9. Release the E-ring (1) that holds the Rubber
Registration Roll Gear (2) from the Paper HandlingAsm.
10. Slide the Rubber Registration Roll Gear off thePaper Handling Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 489
Toner Cartridge Key Sensor
1
2
HK
A04
6FA
Left
Right
Back Side
Parts Reference: Toner Cartridge Key Sensor
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Remove the Toner Cartridge Top Guide (p. 491)9. Release the Harness (1) of the Toner Cartridge Key
Sensor from three clamps of the Toner CartridgeTop Guide.
10. Use a small screwdriver to remove the right shaft ofthe Toner Cartridge Key Sensor (2) from the rightbracket of the Toner Cartridge Top Guide.
11. Use a small screwdriver to remove the left shaft ofthe Toner Cartridge Key Sensor from the leftbracket of the Toner Cartridge Top Guide.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 490
Toner Cartridge Top GuideParts Reference: Toner Cartridge Top Guide
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Remove the Controller Cover (p. 348).5. Remove the Left Cover (p. 408).6. Remove the Top Cover (p. 493).7. Remove the PCB Cover Plate (p. 467).8. Disconnect P/J25 from the MCU PCB (p. 415).9. Remove the two screws (1) that hold the Toner
Cartridge Top Guide (2) to the printer.10. Remove the Toner Cartridge Top Guide from the
printer.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 491
Toner Sensor AsmParts Reference: Toner Sensor Asm
Removal :1. Open the Front Cover Asm (p. 391).2. Remove the left side of the Toner Sensor Asm (1)
from the Paper Handling Asm.3. Remove the right side of Toner Sensor Asm from the
Paper Handling Asm.4. Disconnect P/J421 (2) from the Toner Sensor Asm.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 492
Top CoverParts Reference: Top Cover
Removal :1. Remove the Front Cover Asm (p. 391).2. Remove the 550-Sheet Tray Asm (p. 325).3. Remove the Front Left Cover (p. 395).4. Open the Rear Cover Asm.5. Remove the four screws (1) that hold the Top Cover
(2) to the printer.6. Raise the Top Cover slightly. Then disconnect
P/J363 (not shown) from the bottom of the OperatorPanel.
7. Remove the Top Cover.
Replacement: Reverse the removal procedure. Makesure the Top Cover properly fits with the Left Cover,Controller Cover, and Right Cover.
Chapter 5. Removals and Replacements 493
Tray ConnectorParts Reference: Tray Connector
Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the four screws (1) that hold the two Tray
Motor Brackets (2, 4) to the 550-Sheet Tray Asm.3. Remove the two Tray Motor Springs (3, 5) from the
550-Sheet Tray Asm.
Continued on p. 495.
Chapter 5. Removals and Replacements 494
6 HK
A09
8FC
10
7
9
8
Right
Left
Parts Reference: Tray Connector
Continued from p. 494.4. Disconnect P/J673 (8) from the Tray Connector (7).5. Remove the two screws (6) that hold the Tray
Connector Guide (10) to the 550-Sheet Tray Asm.6. Remove the Tray Connector and the Tray Connector
Guide from the 550-Sheet Tray Asm.7. Remove the Tray Connector Spring (9).8. Slide the Tray Connector upward, and then
disconnect it from the Tray Connector Guide.
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 495
Tray Lift Motor AsmParts Reference: Tray Lift Motor
Removal :1. Remove the 550-Sheet Tray Asm.2. Remove the four screws (1) that hold the two Tray
Motor Brackets (2, 4) to the 550-Sheet Tray Asm.3. Remove the two Tray Motor Springs (3, 5) from the
550-Sheet Tray Asm.
Continued on p. 497.
Chapter 5. Removals and Replacements 496
Parts Reference: Tray Lift Motor
Continued from p. 496.4. Disconnect P/J673 (6) from the Tray Connector.5. Remove the three screws (8).6. Remove the Tray Lift Motor Asm (7).
Replacement: Reverse the removal procedure.Note: During installation, make sure the Tray Lift MotorAsm properly fits with the Tray Lift Shaft.
Chapter 5. Removals and Replacements 497
Tray Retard Clutch - FrictionParts Reference: Tray Retard Clutch - Friction
Removal :1. Remove the 550-Sheet Tray Asm.2. Release the left and right latches (1) of the
550-Sheet Tray Asm and open the Tray RetardChute (2).
Continued on p. 499.
Chapter 5. Removals and Replacements 498
Parts Reference: Tray Retard Clutch - Friction
Continued from p. 498.3. Remove the Tray Retard Roll (p. 500).4. Slide the Tray Retard Clutch (Friction) (3) off the
Tray Retard Shaft (4).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 499
Tray Retard RollParts Reference: None
Removal :1. Remove the 550-Sheet Tray Asm.2. Release the left and right latches (1) of the
550-Sheet Tray Asm and open the Tray RetardChute (2).
Continued on p. 501.
Chapter 5. Removals and Replacements 500
Parts Reference: None
Continued from p. 500.3. Unhook the latch on the Tray Retard Roll (3) and
slide the Tray Retard Roll off the Tray Retard Shaft(4).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 501
Tray Retard SpringParts Reference: Tray Retard Spring
Removal :1. Remove the 550-Sheet Tray Asm.2. Release the left and right latches (1) of the
550-Sheet Tray Asm and open the Tray RetardChute (2).
Continued on p. 503.
Chapter 5. Removals and Replacements 502
4
3
HK
A09
5FB
Right
Left
Parts Reference: Tray Retard Spring
Continued from p. 502.3. Open the Tray Retard Bracket (3).4. Remove the Tray Retard Spring (4).
Replacement: Reverse the removal procedure.
Chapter 5. Removals and Replacements 503
Chapter 6. Parts Catalog
Using the Parts Catalog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510Approved Cleaners and Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 511Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 512Printer Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514
Assembly 1: Covers 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 514Assembly 2: Covers 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 517Assembly 3: Covers 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 519Assembly 4: 550-Sheet Tray Asm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 521Assembly 5: 550-Sheet Tray Asm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523Assembly 6: Paper Feeder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 526Assembly 7: Aux Tray Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 530Assembly 8: P/H Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 533Assembly 9: Chute Transfer and Fuser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536Assembly 10: Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 538Assembly 11: Drive and Xerographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 541Assembly 12: Frame and Size Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 543Assembly 13: Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 546Assembly 14: Optional Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549Assembly 15: Optional Tray 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 552Assembly 16: Envelope Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 556Assembly 17: Envelope Feeder 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559Assembly 18: Duplex 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 562Assembly 19: Duplex 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564Assembly 20: Offset Output Bin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 567Assembly 21: Offset Output Bin 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 569
Parts Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573550-Sheet Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5735 V DC PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573
© Copyright IBM Corp. 2000 504
Actuator And Support Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 573Aux Drive Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Drive Gear Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Roll. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574Aux Pick Up Pad Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 575Aux Tray Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bearing Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576Bias Transfer Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 576BTR Support Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Coax NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Compact Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 577Controller Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Controller PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 578Duplex Face-up Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Connector - Female . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env No-Paper Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 579Env Tray Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Ethernet NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 580Exit Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 581Exit Roll 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Roll 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Exit Static Eliminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583Feed Chute Pinch Roll Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 583
Chapter 6. Parts Catalog 505
Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Feed Roll Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584Font Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 585Front Cover Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Front Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 586Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 120 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Asm 230 v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 587Fuser Stop Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Gear Drive Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Hard Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 588Harness (AC - J285) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J1 - J101) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J21 - J211, J212, J213) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 589Harness (J22 - J223) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J23 - J231) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J25 - J251) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 590Harness (J26 - J261) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J27, J11, J262-J271). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J28 - J281) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 591Harness (J282 - J9, J288 - J9). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J31 - J311). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J33 - J331) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 592Harness (J34 - J341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J34 - P341) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J35 - J351) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 593Harness (J4 - Operator Panel) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594
Chapter 6. Parts Catalog 506
Harness (J42 - J421) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J43 - J432, J433) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 594Harness (J45 - J451) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J51 - J511). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595Harness (J66 - J661, J662) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595HVPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596IBM AFP/IPDS Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Interface PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 596Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597Left Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 120V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 597LVPS 230V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598Main Power Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 598MCU PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Memory DIMM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599No Paper Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 599Offset Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Direction Home Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Exit Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600Offset Full Stack Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Full Stack Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Offset Paper Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601Operator Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Feed PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Left Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Drawer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603Option Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604
Chapter 6. Parts Catalog 507
Option Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 604Option Pick Roll Asm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Right Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Option Top Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 605Paper Handling Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Low Photo Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 606Paper Size Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Pick Roll Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 607Rear Cover Asm (With Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Asm (Without Face-Up Bin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 608Rear Cover Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Actuator Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 609Registration Clutch - Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Registration Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 610Right Registration Roll Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611ROS Asm (Laser) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Token Ring NIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 611Toner Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Key Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Cartridge Top Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 612Toner Sensor Asm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Lift Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 613Tray Retard Clutch - Friction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614Tray Retard Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Chapter 6. Parts Catalog 508
Twinax NIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 614
Chapter 6. Parts Catalog 509
Using the Parts CatalogA table describing the individual assembly parts follows each assembly illustration. A description of the tableentries follows:
Asm.–Index Part Number Description
1– 63H0000 Cover asm. (Contains 100-1, -4)
–1 63H0001 Front Cover
–2 63H0002 Top Cover
–3 N/P Left Top Cover Hinge
–4 N/P Top Cover Right Hinge
–99 63H0003 Kit, top cover mounting with 3 and 4
Asm– Index
Each number in this column corresponds to a number in the assembly illustration.
Part Number
This is the IBM part number for the part listed in the Asm– Index column. ″N/P″ (not procurable) in this columnindicates the part cannot be ordered individually. Order the subassembly or assembly to which the part belongs.
Description
This is a description of the assembly or part.
Chapter 6. Parts Catalog 510
Approved Cleaners and Lubricants
Table 93. Approved Cleaners and Lubricants
Cleaner orLubricant Use Part
Number Remarks
Cleaner Cleaning metal parts 2286522 Solvent based cleaner
Cover cleaner Cleaning plastic, rubber, and external parts 6933028 Water based, mild detergent
Grease Lubricating Gear teeth 1280441 General purpose grease, medium weight
Oil Lubricating gear shafts and bearings 1280443 General purpose oil, medium weight
Chapter 6. Parts Catalog 511
Optional FeaturesThe following table lists the part numbers that customer engineers can order to replace defective featureelectronic parts.
If a customer wants to order optional features, they should contact an IBM Authorized Dealer or IBM SalesRepresentative.Table 94. Optional Features
Feature Feature Number Part Number
Paper Drawer/550-Sheet A4/Letter 4501 38L1395
550-Sheet Tray - A4/Letter (extra) 4503 38L1396
Offset Output Bin 4620 38L1398
Envelope Feeder 4620 38L1397
Duplex Unit 4402 38L1394
IBM Infoprint Token Ring 4/16 PCI Adapter (Token-Ring NIC) 4120 02N8367
IBM Infoprint Ethernet 10/100 PCI Adapter (Ethernet NIC) 4162 02N8368
IBM AFP/IPDS Module 4820 02N6723
IBM Coax SCS Interface (Coax NIC) 4171 02N8370
IBM Twinax SCS Interface (Twinax NIC) 4141 02N8369
32MB Memory DIMM 4332 38L1405
64MB Memory DIMM 4364 38L1406
128MB Memory DIMM 4390 38L1407
Hard Drive 4328 38L1408
PC Parallel Cable (Type C) 4180 38L1409
6 foot US (Chicago) Line Cord 9250 63H5828
Chapter 6. Parts Catalog 512
Table 94. Optional Features (continued)
Feature Feature Number Part Number
Resource Flash Memory Module 4032 02N6434
Chapter 6. Parts Catalog 513
Printer Assemblies
Assembly 1: Covers 1
Chapter 6. Parts Catalog 514
Asm. -Index Part Number Description
1-01 02N6691 Left Cover
-02 02N6692 Controller Cover
-04 02N6693 Exit Cover
-05 02N6694 Top Cover (includes 1-23)
-06 02N6695 Operator Panel (includes 1-07)
-07 02N6696 Operator Panel Harness
-08 02N6697 Right Cover
-09 02N6698 Front Cover Asm (includes 1-10 to 1-13, 1-15 to 1-17, and 1-20)
-10 Front Cover Panel
-11 Front Cover Left Latch
-12 Front Cover Lever
-13 Front Cover Right Latch
-14 02N6699 Front Cover Stop
-15 Front Cover Env Chute
-16 02N6700 Aux Tray Stop
-17 02N6701 Aux Tray
-19 02N6702 Front Left Cover
-20 Aux Tray Paper Guide
-21 Env Gear Cover
-22 Aux Tray Stop Clip
-23 Top Cover Earth Spring
-24 Front Cover Stop Spring Joint
Chapter 6. Parts Catalog 515
Asm. -Index Part Number Description
-25 Front Cover Stop Spring
Chapter 6. Parts Catalog 516
Assembly 2: Covers 2
99 (with1~9)
98 (7(2x))
Chapter 6. Parts Catalog 517
Asm. -Index Part Number Description
2-01 Rear Cover Latch Spring (same as 3-02)
-02 Rear Cover Left Latch (same as 3-03)
-03 Rear Cover Right Latch (same as 3-04)
-04 Rear Cover Latch Guide (same as 3-05)
-05 Rear Cover Plate (same as 3-06)
-06 Rear Cover Arm (same as 3-12)
-07 Fuser Stop (same as 3-17)
-08 Rear Cover Chute
-09 Rear Cover Pivot Stop (same as 3-14)
-10 02N6704 Rear Cover Stop (same as 3-16)
-11 Duplex Left Guide Rail
-12 Duplex Right Guide Rail
-13 Face-Up Cover
-98 Fuser Stop Kit (includes 2 x 2-07)
-99 02N6705 Rear Cover Asm (Without Face-Up Bin) (includes 2-01 to 2-09 and 2-13 )
Chapter 6. Parts Catalog 518
Assembly 3: Covers 3
Chapter 6. Parts Catalog 519
Asm. -Index Part Number Description
3-01 38L1399 Rear Cover Asm (With Face-Up Bin) (includes 3-02 to 3-15, 3-17 to 3-19)
-02 Rear Cover Latch Spring (same as 2-01)
-03 Rear Cover Left Latch (same as 2-02)
-04 Rear Cover Right Latch (same as 2-03)
-05 Rear Cover Latch Guide (same as 2-04)
-06 Rear Cover Plate (same as 2-05)
-07 Face Up Bin Extension
-08 Face Up Bin
-10 Pinch Roller Spring (same as 10-14)
-11 Pinch Roller (same as 10-12)
-12 Face Up Direction Lever (same as 2-06)
-13 02N6707 (notstocked)
Face Up Chute
-14 Rear Cover Pivot Stop (same as 2-09)
-15 Ground Spring
-16 02N6704 Rear Cover Stop (same as 2-10)
-17 Fuser Stop (same as 2-07)
-18 Rear Cover Chute Cover
-19 Face-Up Bin Static Eliminator
Chapter 6. Parts Catalog 520
Assembly 4: 550-Sheet Tray Asm 1
Same as 5-01
Chapter 6. Parts Catalog 521
Asm. -Index Part Number Description
4-01 38L1396 550-Sheet Tray Asm (includes 4-02 to 4-23)
-02 Tray Paper Support Plate
-05 Tray Paper Length Stop
-06 Tray Housing Extension
-07 Tray Paper Length Position
-08 Tray Paper Length Spring
-09 Tray Latch Spring
-10 Tray Paper Length Plate
-11 Tray Base Extension
-12 Tray Left Paper Width Plate
-13 Tray Right Paper Width Plate
-14 Tray Link
-15 Tray Base Plate
-16 Tray Paper Width Rack
-17 Tray Paper Width Pinion
-18 Tray Sub Asm (same as 5-01)
-19 Tray Paper Length Actuator
-20 Tray Paper Length Actuator Cover
-21 Tray Button Label
-22 Tray Indicator Label
-23 Tray Base Plate Label
Chapter 6. Parts Catalog 522
Assembly 5: 550-Sheet Tray Asm 2
Same as 4-18
Chapter 6. Parts Catalog 523
Asm. -Index Part Number Description
5-01 Tray Sub Asm (same as 4-18) (includes 5-02 to 5-27)
-02 Tray Retard Chute Latch Cover
-03 Tray Retard Chute Left Latch
-04 Tray Retard Chute
-05 Tray Retard Chute Right Latch
-06 Tray Retard Shaft
-07 02N6710 Tray Retard Clutch - Friction
-08 Tray Retard Roll
-09 Tray Retard Bracket
-10 02N6711 Tray Retard Spring
-11 Tray Lift Plate
-12 Tray Lift Shaft
-13 Tray Lift Shaft Support
-14 Bearing
-15 Tray Lift Shaft Ground Spring
-16 Tray Housing
-17 Tray Paper Empty Display Lever
-18 Tray Front Cover
-19 Tray Motor Spring
-20 Tray Right Motor Bracket
-21 Tray Left Motor Bracket
-22 02N6712 Tray Lift Motor
Chapter 6. Parts Catalog 524
Asm. -Index Part Number Description
-24 Tray Lift Motor Support
-25 02N6713 (notstocked)
Tray Connector
-26 Tray Connector Spring
-27 Tray Connector Guide
Chapter 6. Parts Catalog 525
Assembly 6: Paper Feeder
45
98 (with2~40)
96 (with39,40)
97 (with11,12)
98 (with26 (3x) and 5.08)
Chapter 6. Parts Catalog 526
Asm. -Index Part Number Description
6-01 02N6714 Feed Roll Asm (includes 6-02)
-02 Feed Roll Clutch
-03 Feed Roll Spring
-04 02N6715 Feed Roll Chute Spring
-05 Feed Roll Chute Cover
-06 02N6716 (notstocked)
No Paper Actuator
-07 No Paper Actuator Support
-08 Feed Frame
-09 Feed Clamp
-10 Feed Latch Spring
-11 Low Paper Actuator
-12 Low Paper Actuator Support
-13 02N6717 Paper Low Photo Sensor
-14 02N6718 (notstocked)
Harness (J66 - J661, J662)
-15 Feed Position Plate
-17 Feed Chute Pinch Roll
-18 Feed Cover
-19 02N6719 Pick Roll Asm (includes 6-20 to 6-29)
-20 Pick Roll Shaft
-21 Bearing
Chapter 6. Parts Catalog 527
Asm. -Index Part Number Description
-22 Pick Roll Support
-23 Pick Roll Clutch
-24 Pick Roll Clutch Support
-25 Pick Roll Clutch Interlock
-26 Pick Roll
-27 Pick Gear 25T
-28 Pick Gear 31T
-29 Pick Roll Support Spring
-30 Feed Gear 4
-31 Feed Gear 2
-32 Feed Gear Cover
-33 Feed Bracket
-34 Feed Gear 3
-35 Feed Gear 1
-36 02N6720 Feed PCB
-37 02N6721 Pick Clutch - Electric
-38 Bearing
-39 Harness (J67 - J671)
-40 Pick Tray Connector
-41 Feed Chute Pinch Roll Support
-42 Feed Chute Pinch Roll Turn
-43 Feed Chute Tray Stop
Chapter 6. Parts Catalog 528
Asm. -Index Part Number Description
-44 Feed Bracket Clamp
-45 02N6717 Lift Control Photo Sensor (same as 6-13)
-96 02N7015 Connector And Harness Kit (includes 6-39, 6-40)
-97 02N7964 Actuator And Support Kit (includes 6-11, 6-12)
-98 02N6724 Feed Asm (includes 6-01 to 6-45)
-99 02N6725 (notstocked)
Pick And Retard Roll Kit (includes 5-08, 2 x 6-26)
Chapter 6. Parts Catalog 529
Assembly 7: Aux Tray Chute
99 (with9,10)
Chapter 6. Parts Catalog 530
Asm. -Index Part Number Description
7-01 02N6726 Aux Tray Asm (includes 7-02 to 7-31)
-02 Aux Pick Roll Asm (includes 7-03 to 7-06, 7-28)
-03 Aux Pick Roll Shaft
-04 Aux Pick Roll Right Cam
-05 Aux Pick Roll Core
-06 02N6727 Aux Pick Roll
-07 Bearing
-08 Aux Tray Bottom Asm (includes 7-11, 7-12)
-11 Aux Tray Bottom
-12 02N6728 (notstocked)
Aux No Paper Actuator
-13 Aux Tray Bottom Spring
-14 Clip Bearing
-15 02N6729 (notstocked)
Aux Retard Pad Asm
-19 02N6717 (notstocked)
Aux No Paper Photo Sensor (same as 6-13)
-20 Aux Tray Ground Plate
-21 Aux Tray Frame
-23 02N6731 (notstocked)
Aux Pick Up Solenoid
-24 02N6732 (notstocked)
Aux Pick Up Gear Spring
Chapter 6. Parts Catalog 531
Asm. -Index Part Number Description
-25 02N6733 (notstocked)
Aux Pick Up Gear
-26 Env Connector Plate
-27 02N6734 (notstocked)
Env Connector - Female
-28 Aux Pick Roll Left Cam
-29 02N6735 (notstocked)
Harness (J45 - J451)
-30 Env Connector Asm (includes 7-26, 7-27)
-99 02N6736 Aux Pick Up Pad Asm (includes 7-09, 7-10)
Chapter 6. Parts Catalog 532
Assembly 8: P/H Assembly
99 (with1~3,32,33)
Chapter 6. Parts Catalog 533
Asm. -Index Part Number Description
8-01 Toner Sensor
-02 Toner Sensor Bracket
-03 Toner Sensor Spring
-04 02N6737 Paper Handling Asm (includes 8-02, 8-05 to 8-31, 8-36 to 8-39)
-05 Metal Registration Roll
-06 Front Registration Chute
-07 02N6738 (notstocked)
Rubber Registration Roll
-08 Rear Registration Chute
-09 Upper Registration Chute Bottom Ground Spring
-10 02N6739 Registration Actuator
-11 02N6740 Registration Actuator Spring
-12 02N6717 Registration Sensor (same as 6-13)
-13 Left Metal Roll Bearing
-14 02N6742 Right Registration Roll Spring
-15 02N6743 (notstocked)
Metal Registration Roll Gear
-16 02N6744 (notstocked)
Rubber Registration Roll Gear
-17 Right Rubber Roll Bearing
-18 Left Rubber Roll Bearing
-19 02N6745 Registration Clutch - Electric
-20 Upper Registration Chute
Chapter 6. Parts Catalog 534
Asm. -Index Part Number Description
-21 Upper Registration Chute Right Ground Spring
-22 Upper Registration Chute Center Ground Spring
-23 Grounding Screw
-24 Upper Registration Chute Left Ground Spring
-25 Upper Registration Chute Grounding Resistor
-26 Center Registration Chute
-27 Lower Registration Chute
-28 02N6746 (notstocked)
Harness (J43 - J432, J433)
-29 Chute Torsion Spring
-30 Rear Registration Chute Handle
-31 Right Metal Roll Bearing
-32 Harness (J42 - J421)
-33 Toner Sensor Cushion
-34 02N6748 Aux Drive Gear Shaft
-35 02N6749 Aux Drive Gear
-36 02N8366 Left Registration Roll Spring
-37 Inlet Label
-38 Upper Registration Chute Clamp
-39 Rear Registration Chute Cap
-99 02N6750 Toner Sensor Asm (includes 8-01 to 8-03, 8-32, 8-33)
Chapter 6. Parts Catalog 535
Assembly 9: Chute Transfer and Fuser
98 (with2,7)
Chapter 6. Parts Catalog 536
Asm. -Index Part Number Description
9-01 BTR Asm (includes 9-02 to 9-26, 9-13)
-02 02N6751 Bias Transfer Roll
-03 02N6752 BTR Support Asm (includes 9-04 to 9-06, 9-13)
-04 BTR Support Bearing
-05 BTR Support Right Bearing Spring
-06 BTR Support Base
-07 02N6753 (notstocked)
Fuser Asm 120 v (Customer Replaceable Unit)
02N8579 (notstocked)
Fuser Asm 230 v (Customer Replaceable Unit)
-10 Dts Wire
-11 Tr Wire
-12 02N6754 (notstocked)
Harness (J27, J11, J262-J271) (120 v)
-13 BTR Support Left Bearing Spring
-14 BTR Lift
-98 Usage Kit 120V (includes 9-02, 9-07, 3 x 6-26)
Usage Kit 230V (includes 9-02, 9-07, 3 x 6-26)
Chapter 6. Parts Catalog 537
Assembly 10: Exit
26
99 (with1~17,19~24)
98 (with6 (6x))
Chapter 6. Parts Catalog 538
Asm. -Index Part Number Description
10-01 02N6755 Exit Static Eliminator
-02 02N6756 Full Stack Actuator
-03 Offset Exit Gate
-04 Offset Exit Gate Spring
-05 Exit Gear - 17
-06 Bearing
-07 02N6758 Exit Roll 1
-08 Outside Exit Pinch Roll
-09 Inside Exit Pinch Roll
-10 Top Exit Pinch Roll Spring
-11 02N6759 Exit Roll 2
-12 Small Exit Pinch Roll (same as 3-11)
-13 Middle Exit Pinch Roll Spring
-14 Lower Exit Pinch Roll Spring (same as 3-10)
-15 Exit Chute
-16 02N6717 Full Stack Photo Sensor (same as 6-13)
-17 02N6761 (notstocked)
Harness (J31 - J311)
-18 Rear Interlock Switch Cover
-19 Exit Gear - 23
-20 Exit Gear - 33
-21 02N6762 Exit Motor
Chapter 6. Parts Catalog 539
Asm. -Index Part Number Description
-22 Exit Gear - 17/47
-23 Exit Gear - 32
-24 Exit Chute Ground Spring
-25 Bearing
-26 02N6758 Exit Roll 1 (same as 10-07)
-98 02N7032 Bearing Kit (includes 6 x 10-06)
-99 02N6763 Exit Asm (includes 10-01 to 10-17, 10-19 to 10-24)
Chapter 6. Parts Catalog 540
Assembly 11: Drive and Xerographics
99 (with2,5,6)
Chapter 6. Parts Catalog 541
Asm. -Index Part Number Description
11-01 Toner Cartridge (customer replaceable unit - supply)
-02 Harness (J25 - J251)
-03 Toner Cartridge Top Guide Label
-04 02N6764 Toner Cartridge Top Guide
-05 Toner Cartridge Key Sensor Spring
-06 Toner Cartridge Key Sensor
-07 02N6765 (notstocked)
Harness (J21 - J211, J212, J213)
-09 02N6767 ROS Asm (Laser)
-10 Toner Cartridge Right Guide Asm (includes 11-11, 11-12)
-11 Toner Cartridge Right Guide
-12 Toner Cartridge Right Guide Clip
-13 02N6768 Gear Drive Asm
-14 02N6769 Main Motor
-15 Toner Cartridge Right Guide Arm A
-16 Toner Cartridge Right Guide Spring A
-17 Toner Cartridge Right Guide Arm B
-18 Toner Cartridge Right Guide Spring B
-99 02N6770 Toner Cartridge Key Sensor (includes 11-02, 11-05, 11-06)
Chapter 6. Parts Catalog 542
Assembly 12: Frame and Size Sensor
99 (with14~18)
Chapter 6. Parts Catalog 543
Asm. -Index Part Number Description
12-01 PCB Cover Plate
-02 Harness Clamp
-03 Top Harness Clamp
-04 Square Harness Clamp
-05 Controller Front Frame
-06 Controller Lower Frame
-07 02N6771 Fan Motor
-08 Fan Duct
-09 Protective Harness Clamp
-10 Ac Harness Clamp
-11 MCU PCB Back Insulator
-12 Left Handle Plate
-13 02N6772 (notstocked)
Harness (J33 - J331) (same as 14-13)
-14 Paper Size Cam (same as 14-10)
-15 Paper Size Cam Switch (same as 14-11)
-16 Paper Size Front Cover (same as 14-12)
-19 02N6773 Paper Size PCB
-20 02N6774 (notstocked)
Harness (J51 - J511)
-21 Paper Size Housing (same as 14-06)
-22 Earth Spring
Chapter 6. Parts Catalog 544
Asm. -Index Part Number Description
-99 02N6775 Paper Size Sensor Asm (includes 12-14 to 12-18)
Chapter 6. Parts Catalog 545
Assembly 13: Electrical
23
Chapter 6. Parts Catalog 546
Asm. -Index Part Number Description
13-01 02N6776 (notstocked)
Harness J282-J9, J288-J9
-02 01P4807 Controller PCB
-03 Controller Back Panel
-04 02N6777 (notstocked)
Harness (J35 - J351)
-06 Power Cord
-07 02N6779 Rear Cover Interlock Switch
-08 Harness (AC - J85)
-09 02N6780 (notstocked)
Harness (J34 - P341)
-10 02N6781 (notstocked)
Harness (J23 - J231)
-11 02N6782 Interface PCB
-12 02N6783 Front Cover Interlock Switch
-13 02N6784 MCU PCB
-14 02N6785 5 V DC PCB
-15 02N6786 (notstocked)
Harness (J28 - J281)
-17 02N6787 LVPS 120V
02N7027 LVPS 230V
-18 63H2286 Main Power Switch
-19 02N6788 Harness (J26 - J261)
Chapter 6. Parts Catalog 547
Asm. -Index Part Number Description
-20 02N6789 HVPS
-21 HVPS Housing
-23 Harness (J1-J101)
Chapter 6. Parts Catalog 548
Assembly 14: Optional Paper Drawer
Same as 15-01
Same as 4-01
99 (with8~12)
Chapter 6. Parts Catalog 549
Asm. -Index Part Number Description
14-01 38L1395 Option Paper Drawer (includes 14-02 to 14-22)
-02 Option Gear Bracket
-03 02N6791 Option Top Gear
-04 Option Top Front Plate
-05 02N6792 (notstocked)
Option Harness (J52 - J521)
-06 Option Paper Size Sensor Housing (same as 12-21)
-07 02N6793 Option Paper Size PCB
-10 Option Paper Size Cam (same as 12-14)
-11 Option Paper Size Cam Switch (same as 12-15)
-12 Option Paper Size Front Cover (same as 12-16)
-13 02N6772 (notstocked)
Option Harness (J53 - J531) (same as 12-13)
-14 Option Clamp
-15 Option Frame
-16 02N6795 Option Right Cover
-17 Option Feed Asm (same as 15-01)
-18 550-Sheet Tray Asm (same as 4-01)
-19 Option Left Cover
-20 02N8375 Option Securing Screw
-21 Option Earth Spring
-22 Option Tray Stop
Chapter 6. Parts Catalog 550
Asm. -Index Part Number Description
-23 Option Securing Screw Kit (includes 3 x 14-20)
-99 02N7007 Option Paper Size Sensor Asm (includes 14-08 to 14-12)
Chapter 6. Parts Catalog 551
Assembly 15: Optional Tray 2
Same as 14-17
45
Chapter 6. Parts Catalog 552
Asm. -Index Part Number Description
15-01 02N6798 Option Feed Asm (includes 15-02 to 15-44)
-02 02N6799 Option Pick Roll Asm (includes 15-03)
-03 Option Feed Roll Clutch
-04 Option Feed Roll Spring
-05 Option Chute Spring
-06 02N6716 (notstocked)
Option No Paper Actuator (same as 6-06)
-07 Option No Paper Actuator Support
-08 Option Feed Frame
-09 Option Feed Clamp
-10 Option Latch Spring
-11 Option Low Paper Actuator
-12 Option Low Paper Actuator Support
-13 02N6717 Option Lift Control Photo Sensor (same as 6-13)
-14 02N6718 (notstocked)
Option Sensor Cable (same as 6-14)
-15 Option Feed Position Plate
-17 Option Chute Pinch Roll
-18 Option Cover
-19 02N6719 Option Pick Roll Asm (includes 15-20 to 15-29)
-20 Option Pick Roll Shaft
-21 Bearing
Chapter 6. Parts Catalog 553
Asm. -Index Part Number Description
-22 Option Pick Roll Support
-23 Option Pick Roll Clutch
-24 Option Pick Roll Clutch Support
-25 Option Pick Roll Clutch Interlock
-26 Option Pick Roll
-27 Option Pick Gear 25T
-28 Option Pick Gear 31T
-29 Option Pick Roll Support Spring
-30 Option Gear 4
-31 Option Gear 2
-32 Option Gear Cover Support
-33 Option Gear Cover
-34 Option Gear 3
-35 Option Gear 1
-36 02N6720 Option Feed PCB (same as 6-36)
-37 02N6721 Option Pick Clutch - Electric (same as 6-37)
-38 Bearing
-39 Option Socket Cable (same as 6-39)
-40 Option Socket (same as 6-40)
-41 Option Chute Pinch Roll Support
-42 Option Chute Pinch Roll Turn
-43 Option Chute Tray Stop
Chapter 6. Parts Catalog 554
Asm. -Index Part Number Description
-44 Option Feed Bracket Clamp
-45 02N6717 Option Lift Control Photo Sensor (same as 6-13)
Chapter 6. Parts Catalog 555
Assembly 16: Envelope Feeder
Same as 17-01
99 with (3~8)
Chapter 6. Parts Catalog 556
Asm. -Index Part Number Description
16-01 38L1397 Env Tray Asm (includes 16-02 to 16-30)
-02 02N6809 (notstocked)
Env Top Cover
-03 Env Retard Spring
-04 Env Retard Support
-05 Env Clutch - Torque 29
-06 Env Retard Shaft (includes 16-07)
-07 Env Retard Roll
-08 Bearing
-11 Env Arm Weight
-12 Env Lower Arm Weight
-13 Env Paper Width Left Guide
-14 Env Paper Width Right Guide
-16 Env Feed Asm (same as 17-01)
-17 Env Pinion Gear
-19 Env Bottom Cover
-20 Env Tray Extension
-22 Harness (J412 - J417)
-23 02N6812 (notstocked)
Env Exit Photo Sensor
-24 Env Weight Cover
-26 Env Top Cover Chute
Chapter 6. Parts Catalog 557
Asm. -Index Part Number Description
-27 Env Pinch Spring
-28 Env Pinch Cap
-29 Env Pinch Shaft
-30 Env Pinch Roll
-99 02N6813 (notstocked)
Env Retard Roll Asm (includes 16-03 to 16-08)
Chapter 6. Parts Catalog 558
Assembly 17: Envelope Feeder 2
Same as 16-16
Chapter 6. Parts Catalog 559
Asm. -Index Part Number Description
17-01 Env Feed Asm (includes 17-02 to 17-34)
-02 Env Gear Cover
-03 Env Gear 29
-04 Env Drive Gear 21
-05 Env Gear 23
-06 Env Clutch - Torque 25
-07 Bearing
-08 Env Idler Gear
-09 Env Clutch - One Way 26
-10 Bearing
-11 Env Clutch - Electric
-12 Env Shaft Clutch - Electric
-13 02N8578 (notstocked)
Env Clutch - One Way 26A
-15 Env Roll Shaft (includes 17-16)
-16 Env Transfer Roll
-17 Env Bottom Roll
-18 Env Pinch Roll (same as 16-21)
-19 Env Feed Belt
-20 Env Frame
-21 02N6814 (notstocked)
Env No-Paper Actuator
Chapter 6. Parts Catalog 560
Asm. -Index Part Number Description
-22 02N6815 (notstocked)
Env No Paper Photo Sensor (same as 6-13)
-23 Env Roll Shaft 2
-25 Env Roll Shaft 3 (includes 17-26)
-26 Env Lower Roll
-30 Env Connector - Male
-31 Harness (J411 - J418)
-32 Harness (J413 - J416)
-33 Env PCB
-34 Harness (J414 - J415)
Chapter 6. Parts Catalog 561
Assembly 18: Duplex 1
Chapter 6. Parts Catalog 562
Asm. -Index Part Number Description
18-01 38L1394 Duplex Asm (includes 18-02 to 18-06)
-02 Duplex Upper Guide
-03 Duplex Connector Asm
-04 02N6817 (notstocked)
Duplex Top Cover
-05 Duplex Motor Cover
-06 Duplex Sub Asm (same as 19-01)
Chapter 6. Parts Catalog 563
Assembly 19: Duplex 2
Same as 18-06
Chapter 6. Parts Catalog 564
Asm. -Index Part Number Description
19-01 Duplex Sub Asm (includes 19-02 to 19-19)Note: This part is not stocked. In its place, order 18-01, Duplex Asm, part number 38L1394.
-02 02N6818 (notstocked)
Duplex Roll
-03 02N6819 (notstocked)
Duplex Roll Retaining Clip
-04 Duplex Gear 17/Pulley
-05 Duplex Roll Bearing
-06 Duplex Gear 18
-07 Duplex Gear 17/39
-08 02N6820 (notstocked)
Duplex Motor
-09 02N6821 (notstocked)
Duplex Drive Belt
-10 Duplex Frame
-11 Duplex Latch
-12 Duplex Latch Spring
-13 Harness (J360 - J361)
-14 02N6717 Duplex Face-up Photo Sensor (same as 6-13)
-16 02N6823 (notstocked)
Duplex PCB
-17 Duplex Bottom Cover
-18 02N6824 (notstocked)
Duplex Paper Photo Sensor
Chapter 6. Parts Catalog 565
Asm. -Index Part Number Description
-19 Duplex Label
Chapter 6. Parts Catalog 566
Assembly 20: Offset Output Bin 1
Same as 21-01
Chapter 6. Parts Catalog 567
Asm. -Index Part Number Description
20-01 38L1398 Offset Asm (includes 20-02 to 20-17)
-02 02N6826 Offset Exit Asm
-03 Offset Tray Spring
-04 02N6827 (notstocked)
Offset Exit Bin
-06 02N6828 Offset Paper Weight
-07 02N6829 (notstocked)
Offset Rear Cover
-11 02N6830 (notstocked)
Offset Top Cover
-12 Offset Inner Asm (same as 21-01)
-13 Offset Top Cover Hook
-14 Offset Lower Cover
-15 Offset Rear Cover Spring Support
-16 Offset Rear Cover Left Spring
-17 Offset Rear Cover Right Spring
Chapter 6. Parts Catalog 568
Assembly 21: Offset Output Bin 2
Same as 20-12
Chapter 6. Parts Catalog 569
Asm. -Index Part Number Description
21-01 02N6831 (notstocked)Note: Order20-01, OffsetAsm, partnumber38L1398
Offset Inner Asm (includes 21-02 to 21-45)Note: This part is not stocked. In its place, order 20-01, Offset Asm, part number 38L1398.
-02 Harness (J21 - P202)
-03 Offset PCB Support
-04 02N6832 (notstocked)
Offset PCB
-05 Offset Ground Plate
-06 02N6833 (notstocked)
Offset Drive Motor
-07 Offset Exit Gear 20
-08 Bearing
-09 Offset Gear 27
-10 Offset Gear 26
-11 Offset Gear 47W
-12 Offset Exit Gear
-13 Offset Eliminator
-14 Offset Frame
-15 02N6834 (notstocked)
Offset Direction Solenoid
Chapter 6. Parts Catalog 570
Asm. -Index Part Number Description
-16 02N6835 (notstocked)
Offset Direction Solenoid Lever
-17 Offset Direction Solenoid Pin
-18 02N6836 (notstocked)
Offset Exit Photo Sensor
-19 02N6837 Offset Full Stack Actuator
-20 02N6717 Offset Full Stack Photo Sensor (same as 6-13)
-21 Harness (J224 - J225, J226, J227, J228)
-22 Offset Mech Roll Asm (includes 21-23 to 21-26, 21-45)
-23 Offset Exit Roll
-24 Offset Exit Pinch Roll
-25 Bearing
-26 Offset Exit Guide
-27 Offset Mechanism Asm Support
-28 Offset Mechanism Shaft
-29 Offset Roll Shaft
-30 Offset Pinch Roll
-31 Offset Pinch Roll Spring
-32 02N6839 (notstocked)
Offset Inner Chute Cover
-34 02N6840 (notstocked)
Offset Mechanism Asm (includes 21-35 to 21-39)
Chapter 6. Parts Catalog 571
Asm. -Index Part Number Description
-35 Offset Mechanism Motor
-36 Offset Mechanism Motor Cover
-37 02N6717 Offset Direction Home Sensor (same as 6-13)
-38 Offset Mechanism Lever
-39 Offset Mechanism Gear
-40 Offset Ferrite Core
-41 Offset Ground Wire
-43 Offset Full Stack Sensor Bracket
-44 Offset Harness Clamp
-45 Offset Exit Guide Spring
Chapter 6. Parts Catalog 572
Parts Reference
550-Sheet Tray AsmPart Number : 38L1396Parts Catalog : 04-01 “Assembly 4: 550-Sheet Tray Asm 1” on page 521Locations :Removals/Adjustments : “550-Sheet Tray Asm” on page 325Diagnostics :
5 V DC PCBPart Number : 02N6785Parts Catalog : 13-14 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “5v DC PCB” on page 326Theory : p. 620Diagnostics :
Actuator And Support KitPart Number : NoneParts Catalog : 6-97 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 573
Aux Drive GearPart Number : 02N6749Parts Catalog : 8-35 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Aux Drive Gear Shaft and Aux Drive Gear” on page 327Diagnostics :
Aux Drive Gear ShaftPart Number : 02N6748Parts Catalog : 8-34 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Aux Drive Gear Shaft and Aux Drive Gear” on page 327Diagnostics :
Aux Pick RollPart Number : 02N6727Parts Catalog : 7-06 “Assembly 7: Aux Tray Chute” on page 530Locations : “Rollers” on page 314Removals/Adjustments : “Aux Pick Roll” on page 332Diagnostics :
Chapter 6. Parts Catalog 574
Aux Pick Up Pad AsmPart Number : 02N6736Parts Catalog : 7-99 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “Aux Pick Up Pad Asm” on page 337Diagnostics :
Aux TrayPart Number : 02N6701Parts Catalog : 1-17 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : “Aux Tray” on page 341Diagnostics :
Aux Tray AsmPart Number : 02N6726Parts Catalog : 7-01 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “Aux Tray Asm” on page 342Diagnostics :
Chapter 6. Parts Catalog 575
Aux Tray StopPart Number : 02N6700Parts Catalog : 1-16 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : NoneDiagnostics :
Bearing KitPart Number : NoneParts Catalog : 10-98 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :
Bias Transfer RollPart Number : 02N6751Parts Catalog : 9-02 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Bias Transfer Roll” on page 346Theory : p. 620Diagnostics :
Chapter 6. Parts Catalog 576
BTR Support AsmPart Number : 02N6752Parts Catalog : 9-03 “Assembly 9: Chute Transfer and Fuser” on page 536Locations :Removals/Adjustments : “BTR Support Asm” on page 347Diagnostics :
Coax NICPart Number : 02N8370Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Compact FlashPart Number : 02N8761Parts Catalog :Locations :Removals/Adjustments :Diagnostics :
Chapter 6. Parts Catalog 577
Controller CoverPart Number : 02N6692Parts Catalog : 1-02 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Controller Cover” on page 348Diagnostics :
Controller PCBPart Number : 01P4807Parts Catalog : 13-02 “Assembly 13: Electrical” on page 546Locations : “Controller” on page 309Removals/Adjustments : “Controller PCB” on page 349Theory : p. 620Diagnostics :
Duplex AsmPart Number : 38L1394Parts Catalog : 18-01 “Assembly 18: Duplex 1” on page 562Locations : “Optional Features” on page 312Removals/Adjustments : “Duplex Asm” on page 350Diagnostics :
Chapter 6. Parts Catalog 578
Duplex Face-up Photo SensorPart Number : 02N6717Parts Catalog : 19-14 “Assembly 19: Duplex 2” on page 564Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Duplex Face Up Photo Sensor” on page 354Theory : p. 620Diagnostics : 1020: Sensor/Switch Text
Env Connector - FemalePart Number : 02N6734 (not stocked)Parts Catalog : 7-27 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : “ENV Connector - Female” on page 366Diagnostics :
Env No-Paper ActuatorPart Number : 02N6814 /not stocked)Parts Catalog : 17-21 “Assembly 17: Envelope Feeder 2” on page 559Locations :Removals/Adjustments : “ENV No Paper Actuator” on page 370Diagnostics :
Chapter 6. Parts Catalog 579
Env Tray AsmPart Number : 38L1397Parts Catalog : 16-01 “Assembly 16: Envelope Feeder” on page 556Locations : “Optional Features” on page 312Removals/Adjustments : “ENV Tray Asm” on page 376Diagnostics :
Ethernet NICPart Number : 02N8368Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Exit AsmPart Number : 02N6763Parts Catalog : 10-99 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Asm” on page 379Diagnostics :
Chapter 6. Parts Catalog 580
Exit CoverPart Number : 02N6693Parts Catalog : 1-04 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Exit Cover” on page 380Diagnostics :
Exit MotorPart Number : 02N6762Parts Catalog : 10-21 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Motor” on page 381Theory : p. 620Diagnostics : 1130: Exit Motor CW
Exit Roll 1Part Number : 02N6758Parts Catalog : 10-25 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :
Chapter 6. Parts Catalog 581
Exit Roll 3Part Number : 02N6758Parts Catalog : 10-07 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Exit Roll 1” on page 382Diagnostics :
Exit Roll 2Part Number : 02N6759Parts Catalog : 10-11 “Assembly 10: Exit” on page 538Locations : “Rollers” on page 314Removals/Adjustments : “Bearing and Exit Roll 2” on page 345Diagnostics :
Exit Static EliminatorPart Number : 02N6755Parts Catalog : 10-01 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Exit Static Eliminator” on page 384Diagnostics :
Chapter 6. Parts Catalog 582
Fan MotorPart Number : 02N6771Parts Catalog : 12-07 “Assembly 12: Frame and Size Sensor” on page 543Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fan Motor” on page 386Diagnostics : 1120: Fan Motor High
Feed AsmPart Number : 02N6724Parts Catalog : 6-98 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “Feed Asm” on page 387Diagnostics :
Feed Chute Pinch Roll SupportPart Number : NoneParts Catalog : 6-41 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments :Diagnostics :
Chapter 6. Parts Catalog 583
Feed PCBPart Number : 02N6720Parts Catalog : 6-36 “Assembly 6: Paper Feeder” on page 526Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Feed PCB” on page 389Theory : p. 620Diagnostics :
Feed Roll AsmPart Number : 02N6714Parts Catalog : 6-01 “Assembly 6: Paper Feeder” on page 526Locations : “Rollers” on page 314Removals/Adjustments : “Feed Roll Asm” on page 388Diagnostics :
Feed Roll ClutchPart Number : NoneParts Catalog : 6-02 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneTheory : p. 620Diagnostics : 1250: Tray Feed Clutches
Chapter 6. Parts Catalog 584
Font FlashPart Number : 02N6434Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Front Cover AsmPart Number : 02N6698Parts Catalog : 1-09 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Front Cover Asm” on page 391Diagnostics :
Front Cover Interlock SwitchPart Number : 02N6783Parts Catalog : 13-12 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Front Cover Interlock Switch” on page 392Diagnostics : 1020: Sensor/Switch Text
Chapter 6. Parts Catalog 585
Front Cover StopPart Number : 02N6699Parts Catalog : 1-14 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : NoneDiagnostics :
Front Left CoverPart Number : 02N6702Parts Catalog : 1-19 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Front Left Cover” on page 395Diagnostics :
Full Stack ActuatorPart Number : 02N6756Parts Catalog : 10-02 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : “Full Stack Actuator” on page 396Diagnostics :
Chapter 6. Parts Catalog 586
Full Stack Photo SensorPart Number : 02N6717Parts Catalog : 10-16 “Assembly 10: Exit” on page 538Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Full Stack Photo Sensor” on page 397Theory : p. 620Diagnostics : 1020: Sensor/Switch Text
Fuser Asm 120 vPart Number : 02N6753 (not stocked)Parts Catalog : 09-07 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fuser Asm” on page 398Theory : p. 620Diagnostics :
Fuser Asm 230 vPart Number : 02N8579 (not stocked)Parts Catalog : 09-07 “Assembly 9: Chute Transfer and Fuser” on page 536Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Fuser Asm” on page 398Theory : p. 620Diagnostics :
Chapter 6. Parts Catalog 587
Fuser Stop KitPart Number : NoneParts Catalog : 2-98 “Assembly 2: Covers 2” on page 517Locations :Removals/Adjustments : NoneDiagnostics :
Gear Drive AsmPart Number : 02N6768Parts Catalog : 11-13 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Gear Drive Asm” on page 400Diagnostics :
Hard DrivePart Number : 38L1408Parts Catalog :Locations :Removals/Adjustments :Diagnostics :
Chapter 6. Parts Catalog 588
Harness (AC - J285)Part Number : NoneParts Catalog : 13-08 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J1 - J101)Part Number : NoneParts Catalog : 13-22 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J21 - J211, J212, J213)Part Number : NoneParts Catalog : 11-07 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 589
Harness (J22 - J223)Part Number : 02N6766 (not stocked)Parts Catalog : 11-08 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J23 - J231)Part Number : 02N6781 (not stocked)Parts Catalog : 13-10 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J25 - J251)Part Number : NoneParts Catalog : 11-02 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : “Toner Cartridge Key Sensor” on page 490Diagnostics :
Chapter 6. Parts Catalog 590
Harness (J26 - J261)Part Number : 02N6788Parts Catalog : 13-19 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J27, J11, J262-J271)Part Number : 02N6754 (not stocked)Parts Catalog : 9-12 “Assembly 9: Chute Transfer and Fuser” on page 536Locations :Removals/Adjustments : “Harness (J27, J11, J262 - J271)” on page 401Diagnostics :
Harness (J28 - J281)Part Number : 02N6786 (not stocked)Parts Catalog : 13-15 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 591
Harness (J282 - J9, J288 - J9)Part Number : 02N6776 (not stocked)Parts Catalog : 13-01 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J31 - J311)Part Number : 02N6761 (not stocked)Parts Catalog : 10-17 “Assembly 10: Exit” on page 538Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J33 - J331)Part Number : 02N6772 (not stocked)Parts Catalog : 12-13 “Assembly 12: Frame and Size Sensor” on page 543Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 592
Harness (J34 - J341)Part Number : NoneParts Catalog : 11-09 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : “Harness (J34-P341)” on page 403Diagnostics :
Harness (J34 - P341)Part Number : 02N6780 (not stocked)Parts Catalog : 13-09 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Harness (J34-P341)” on page 403Diagnostics :
Harness (J35 - J351)Part Number : 02N6777 (not stocked)Parts Catalog : 13-04 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Harness (J35 - J351)” on page 404Diagnostics :
Chapter 6. Parts Catalog 593
Harness (J4 - Operator Panel)Part Number : NoneParts Catalog : 11-07 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J42 - J421)Part Number : NoneParts Catalog : 8-32 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Toner Sensor Asm” on page 492Diagnostics :
Harness (J43 - J432, J433)Part Number : 02N6746 (not stocked)Parts Catalog : 8-28 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 594
Harness (J45 - J451)Part Number : 02N6735 (not stocked)Parts Catalog : 7-29 “Assembly 7: Aux Tray Chute” on page 530Locations :Removals/Adjustments : NoneDiagnostics :
Harness (J51 - J511)Part Number : 02N6774 (not stocked)Parts Catalog : 12-20 “Assembly 12: Frame and Size Sensor” on page 543Locations :Removals/Adjustments : “Harness (J51 - J511)” on page 405Diagnostics :
Harness (J66 - J661, J662)Part Number : 02N6718 (not stocked)Parts Catalog : 6-14 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 595
HVPSPart Number : 02N6789Parts Catalog : 13-20 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “HVPS” on page 406Theory : p. 621Diagnostics :
IBM AFP/IPDS ModulePart Number : 02N6723Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Interface PCBPart Number : 02N6782Parts Catalog : 13-11 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Interface PCB” on page 407Theory : p. 621Diagnostics :
Chapter 6. Parts Catalog 596
Left CoverPart Number : 02N6691Parts Catalog : 1-01 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Left Cover” on page 408Diagnostics :
Left Registration Roll SpringPart Number : 02N8366Parts Catalog : 8-36 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Left Registration Roll Spring” on page 410Diagnostics :
LVPS 120VPart Number : 02N6787Parts Catalog : 13-22 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “LVPS” on page 412Theory : p. 621Diagnostics :
Chapter 6. Parts Catalog 597
LVPS 230VPart Number : 02N7027Parts Catalog : 13-17 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “LVPS” on page 412Diagnostics :
Main MotorPart Number : 02N6769Parts Catalog : 11-14 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “Main Motor” on page 413Theory : p. 621Diagnostics :
Main Power SwitchPart Number : 63H2286Parts Catalog : 13-18 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Main Power Switch” on page 414Diagnostics :
Chapter 6. Parts Catalog 598
MCU PCBPart Number : 02N6784Parts Catalog : 13-13 “Assembly 13: Electrical” on page 546Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “MCU PCB” on page 415Theory : p. 621Diagnostics :
Memory DIMMPart Numbers : 38L1405 (32MB), 38L1406 (64MB), 38L1407 (128MB)Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
No Paper ActuatorPart Number : 02N6716 (not stocked)Parts Catalog : 6-06 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “No Paper Actuator” on page 419Diagnostics :
Chapter 6. Parts Catalog 599
Offset AsmPart Number : 38L1398Parts Catalog : 20-01 “Assembly 20: Offset Output Bin 1” on page 567Locations : “Optional Features” on page 312Removals/Adjustments : “Offset Asm” on page 420Diagnostics :
Offset Direction Home SensorPart Number : 02N6717Parts Catalog : 21-37 “Assembly 21: Offset Output Bin 2” on page 569Locations :Removals/Adjustments : “Offset Direction Home Sensor” on page 422Theory : p. 621Diagnostics :
Offset Exit AsmPart Number : 02N6826Parts Catalog : 20-02 “Assembly 20: Offset Output Bin 1” on page 567Locations :Removals/Adjustments : “Offset Exit Bin Asm” on page 425Diagnostics :
Chapter 6. Parts Catalog 600
Offset Full Stack ActuatorPart Number : 02N6837Parts Catalog : 21-19 “Assembly 21: Offset Output Bin 2” on page 569Locations :Removals/Adjustments : “Offset Full Stack Actuator” on page 427Diagnostics :
Offset Full Stack Photo SensorPart Number : 02N6717Parts Catalog : 21-20 “Assembly 21: Offset Output Bin 2” on page 569Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Offset Full Stack Photo Sensor” on page 428Theory : p. 621Diagnostics :
Offset Paper WeightPart Number : 02N6828Parts Catalog : 20-06 “Assembly 20: Offset Output Bin 1” on page 567Locations :Removals/Adjustments : “Offset Paper Weight” on page 433Diagnostics :
Chapter 6. Parts Catalog 601
Operator PanelPart Number : 02N6695Parts Catalog : 1-06 “Assembly 1: Covers 1” on page 514Locations :Removals/Adjustments : “Operator Panel” on page 437Diagnostics :
Option Feed AsmPart Number : 02N6798Parts Catalog : 15-01 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : “Option Feed Asm” on page 439Diagnostics :
Option Feed PCBPart Number : 02N6720Parts Catalog : 15-36 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : NoneTheory : p. 621Diagnostics :
Chapter 6. Parts Catalog 602
Option Pick Roll AsmPart Number : 02N6799Parts Catalog : 15-02 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : “Option Pick Roll Asm” on page 457Diagnostics :
Option Left CoverPart Number : NoneParts Catalog : 14-19 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :
Option Paper DrawerPart Number : 38L1395Parts Catalog : 14-01 “Assembly 14: Optional Paper Drawer” on page 549Locations : “Optional Features” on page 312Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 603
Option Paper Size PCBPart Number : 02N6793Parts Catalog : 14-07 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : “Option Paper Size PCB” on page 452Theory : p. 621Diagnostics :
Option Paper Size Sensor AsmPart Number : 02N6775Parts Catalog : 14-99 “Assembly 14: Optional Paper Drawer” on page 549Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Option Paper Size Sensor Asm” on page 453Diagnostics :
Option Pick Clutch - ElectricPart Number : 02N6721Parts Catalog : 15-37 “Assembly 15: Optional Tray 2” on page 552Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 604
Option Pick Roll AsmPart Number : 02N6719Parts Catalog : 15-19 “Assembly 15: Optional Tray 2” on page 552Locations : “Rollers” on page 314Removals/Adjustments : NoneDiagnostics :
Option Right CoverPart Number : 02N6795Parts Catalog : 14-16 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :
Option Top GearPart Number : 02N6791Parts Catalog : 14-03 “Assembly 14: Optional Paper Drawer” on page 549Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 605
Paper Handling AsmPart Number : 02N6737Parts Catalog : 8-04 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Paper Handling Asm” on page 462Diagnostics :
Paper Low Photo SensorPart Number : 02N6717Parts Catalog : 6-13 “Assembly 6: Paper Feeder” on page 526Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Paper Low Photo Sensor” on page 463Theory : p. 622Diagnostics :
Paper Size PCBPart Number : 02N6773Parts Catalog : 12-19 “Assembly 12: Frame and Size Sensor” on page 543Locations : “PCBs (Printed Circuit Boards)” on page 313Removals/Adjustments : “Paper Sizing PCB” on page 466Theory : p. 622Diagnostics :
Chapter 6. Parts Catalog 606
Paper Size Sensor AsmPart Number : 02N6775Parts Catalog : 12-99 “Assembly 12: Frame and Size Sensor” on page 543Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Paper Size Housing Asm” on page 465Diagnostics :
Pick Clutch - ElectricPart Number : 02N6721Parts Catalog : 6-37 “Assembly 6: Paper Feeder” on page 526Locations :Removals/Adjustments : “Pick Clutch - Electric” on page 468Diagnostics :
Pick Roll AsmPart Number : 02N6719Parts Catalog : 6-19 “Assembly 6: Paper Feeder” on page 526Locations : “Rollers” on page 314Removals/Adjustments : “Pick Roll Asm” on page 471Diagnostics :
Chapter 6. Parts Catalog 607
Rear Cover Asm (With Face-Up Bin)Part Number : 38L1399Parts Catalog : 3-01 “Assembly 3: Covers 3” on page 519Locations : “Covers” on page 310Removals/Adjustments : “Rear Cover Asm” on page 473Diagnostics :
Rear Cover Asm (Without Face-Up Bin)Part Number : 02N6705Parts Catalog : 2-99 “Assembly 2: Covers 2” on page 517Locations : “Covers” on page 310Removals/Adjustments : “Rear Cover Asm” on page 473Diagnostics :
Rear Cover Interlock SwitchPart Number : 02N6779Parts Catalog : 13-07 “Assembly 13: Electrical” on page 546Locations :Removals/Adjustments : “Rear Cover Interlock Switch” on page 474Diagnostics :
Chapter 6. Parts Catalog 608
Rear Cover StopPart Number : 02N6704Parts Catalog : 2-10 “Assembly 2: Covers 2” on page 517, 3-16 “Assembly 3: Covers 3” on page 519Locations :Removals/Adjustments : “Rear Cover Stop” on page 476Diagnostics :
Registration ActuatorPart Number : 02N6739Parts Catalog : 8-10 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Actuator” on page 479Diagnostics :
Registration Actuator SpringPart Number : 02N6740Parts Catalog : 8-11 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Actuator Spring” on page 480Diagnostics :
Chapter 6. Parts Catalog 609
Registration Clutch - ElectricPart Number : 02N6745Parts Catalog : 8-19 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Registration Clutch - Electric” on page 481Theory : p. 622Diagnostics :
Registration SensorPart Number : 02N6717Parts Catalog : 8-12 “Assembly 8: P/H Assembly” on page 533Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Registration Sensor” on page 482Theory : p. 622Diagnostics :
Right CoverPart Number : 02N6697Parts Catalog : 1-08 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Right Cover” on page 483Diagnostics :
Chapter 6. Parts Catalog 610
Right Registration Roll SpringPart Number : 02N6742Parts Catalog : 8-14 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Left Registration Roll Spring” on page 410Diagnostics :
ROS Asm (Laser)Part Number : 02N6767Parts Catalog : 11-09 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments : “ROS Asm (Laser)” on page 485Theory : p. 622Diagnostics :
Token Ring NICPart Number : 02N8367Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Chapter 6. Parts Catalog 611
Toner CartridgePart Number : NoneParts Catalog : 11-01 “Assembly 11: Drive and Xerographics” on page 541Locations : “Major Assemblies, Components, and Supplies” on page 311Removals/Adjustments :Theory : p. 622Diagnostics :
Toner Cartridge Key SensorPart Number : 02N6770Parts Catalog : 11-99 “Assembly 11: Drive and Xerographics” on page 541Locations : “Sensors and Switches” on page 315Removals/Adjustments : “Toner Cartridge Key Sensor” on page 490Theory : p. 622Diagnostics :
Toner Cartridge Top GuidePart Number : 02N6764Parts Catalog : 11-04 “Assembly 11: Drive and Xerographics” on page 541Locations :Removals/Adjustments : NoneDiagnostics :
Chapter 6. Parts Catalog 612
Toner Sensor AsmPart Number : 02N6750Parts Catalog : 8-99 “Assembly 8: P/H Assembly” on page 533Locations :Removals/Adjustments : “Toner Sensor Asm” on page 492Theory : p. 622Diagnostics :
Top CoverPart Number : 02N6694Parts Catalog : 1-06 “Assembly 1: Covers 1” on page 514Locations : “Covers” on page 310Removals/Adjustments : “Top Cover” on page 493Diagnostics :
Tray Lift MotorPart Number : 02N6712Parts Catalog : 5-22 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Lift Motor Asm” on page 496Theory : p. 622Diagnostics :
Chapter 6. Parts Catalog 613
Tray Retard Clutch - FrictionPart Number : 02N6710Parts Catalog : 5-07 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Retard Clutch - Friction” on page 498Diagnostics :
Tray Retard SpringPart Number : 02N6711Parts Catalog : 5-10 “Assembly 5: 550-Sheet Tray Asm 2” on page 523Locations :Removals/Adjustments : “Tray Retard Spring” on page 502Diagnostics :
Twinax NICPart Number : 02N8369Parts Catalog :Locations : “Controller” on page 309Removals/Adjustments :Diagnostics :
Chapter 6. Parts Catalog 614
Chapter 7. Preventive Maintenance
Periodically Replaced Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 615
Preventive maintenance for this printer is the responsibility of the customer. It requires the customer to periodicallyreplace supplies (parts). Although the customer may choose to have a service representative perform thepreventive maintenance (parts replacement) on a “per-call” basis, the customer is still responsible for purchasingthe supplies.
Periodically Replaced SuppliesThe following table lists the supplies and expected lives of customer-replaceable parts. The customer should referto the User’s Guide for replacement of these parts.
Supply Name Customer Part Number Expected Life (approximate)
Toner Cartridge 38L1410 15,000 images
Usage Kit (100-140 Volt) 38L1411 200,000 images
Usage Kit (230 Volt) 38L1412 200,000 images
The initial toner cartridge can print approximately 8,000 pages of Letter-size paper, containing text or graphics thatcover 5% of the page. This yield was established with the default DENSITY setting and QUALITY set to NORMAL(Config Menu). Toner cartridges after the first can print approximately 15,000 pages in the same conditions. TheQUALITY=ECONO setting can increase the life of the toner cartridge by up to 20% to 30%. This yield increasewas established with a toner coverage of 5% on letter-size paper, default DENSITY setting, QUALITY=ECONOsetting, and an average of 3 to 4 pages per print job. (Note that the print driver settings will override all othersettings.)
Note: The actual page yield is affected by the environment, the type of print media, the orientation of the printmedia, the percentage of text and graphics, the complexity of the graphics, and other factors, so actualresults can vary.
© Copyright IBM Corp. 2000 615
Appendix A. Installation
The Infoprint 21 is a customer install and setup product. The customer may, however, choose to have a servicerepresentative perform the installation on a charge-per-call basis or under the terms and conditions of a specialbid.
© Copyright IBM Corp. 2000 616
Appendix B. Drivers, Technical Support, and Warranty Information
Driver Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 617Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Warranty Period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Warranty Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618Dealer Warranty Claim Center (DWCC), U.S.A. only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 618
Maintenance (Service) Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 619
Driver InformationFind the latest level printer drivers at the IBM Printing Systems website at:www.printers.ibm.com
© Copyright IBM Corp. 2000 617
Technical SupportIBM support for this printer is available at no charge when covered by the IBM one-year warranty, or an IBMmaintenance agreement.
If the service procedures that you choose do not solve the problem, return to “MAP 010: Start MAP” on page 44and define the problem again or callv 1-800-358-6661 for technical support in the U.S.A. and Canadav Outside the U.S.A. and Canada, call your country customer service center
Warranty Information
Warranty PeriodIBM warrants this printer for 1 year (12 months).
Warranty ServiceOn-site warranty service can be arranged through IBM. In the U.S.A. and Canada, call 1-800-358-6661.
Dealer Warranty Claim Center (DWCC), U.S.A. onlyTo order warranty parts or to request warranty claim reimbursements through the Dealer Warranty Claim Center,call 1-800-388-7080.
Appendix B. Drivers, Technical Support, and Warranty Information 618
Maintenance (Service) AgreementContact your IBM representative or your local IBM Branch Office for information. In the U.S.A. and Canada youcan call 1-800-358-6661.
Appendix B. Drivers, Technical Support, and Warranty Information 619
Appendix C. Parts Theory5 V DC PCB
The 5v DC PCB supplies 5v DC to the Controller PCB. This 5v is used by the controller PCI modules suchas the Hard Drive and NICs.
Bias Transfer RollThe Bias Transfer Roll is used in the EP process to transfer toner from the drum in the Toner Cartridge on tothe paper.
Controller PCBThe Controller PCB generates the raw page image data and handles communication with the printercontroller and the NIC cards. This PCB also controls the Operator Panel.
Duplex Face-up Photo SensorThe Duplex Face-Up Photo Sensor detects when the Face-Up Bin is open. If the face-up bin is open, duplexcapability is disabled.
Exit MotorThe Exit Motor drives the exit gears and rollers. This motor is also used during duplex printing to move thepaper into the Duplex Asm.
Feed PCBThe Feed PCB controls the pick and feed clutches and the Tray Lift Motor for the tray. The No Paper PhotoSensor is also installed on the Feed PCB.
Feed Roll ClutchThe Feed Roll Clutch operates the feed rolls for each tray, transporting the paper to the registration roller.
Full Stack Photo SensorThe Full Stack Photo Sensor detects when the Main Bin is full of paper. The MCU PCB posts an error code031 after this sensor is continuously activated for 100 printed pages.
Fuser AsmThe Fuser Asm is a customer-replaceable unit that “fuses” or fixes the toner to the paper using heat andpressure.
© Copyright IBM Corp. 2000 620
HVPSThe High Voltage Power Supply supplies high DC and AC voltages to the Toner Cartridge, Bias TransferRoll, and Fuser Asm. These voltages are needed for the EP process.
Interface PCBThe Interface PCB passes signals from the MCU PCB to the Paper Handling Asm, the Envelope Asm andthe Aux Tray.
LVPSThe Low Voltage Power Sopply supplies all signal and motor DC voltages needed by the printer and MCUPCB. The LVPS also supplies 3.3v DC to the Controller PCB that is used for the controller logic.
Main MotorThe Main Motor drives the Gear Drive Asm and associated rollers to move paper from the pick rollers ineach tray to the Fuser Asm.
MCU PCBThe MCU PCB controls all printer functions, including all motors, clutches and sensors. This card is alsoresponsible for posting error codes to the Controller PCB for display on the Operator Panel.
Offset Direction Home SensorThe Offset Direction Home Sensor detects where the Offsetting Mechanism in the Offset Asm is currentlylocated.
Offset Full Stack Photo SensorThe Offset Full Stack Photo Sensor detects when the Offset Bin is full of paper. The MCU PCB posts anerror code 035 after this sensor is continuously activated for 100 printed pages.
Option Feed PCBThe Option Feed PCB controls the pick and feed clutches for the Option Drawer as well as operating theOption Tray Lift Motor. The No Paper Photo Sensor is also included on this PCB.
Option Paper Size PCBThe Option Paper Size PCB passes signals between the Paper Size PCB, the Option Feed PCB, and theTray 3 Option Paper Size PCB, if installed. The Paper Size Switches that are used to detect the currentpaper size in the tray are also installed on this PCB.
Appendix C. Parts Theory 621
Paper Low Photo SensorThe Paper Low Photo Sensor detects when the tray paper supply is less than 50 standard sheets.
Paper Size PCBThe Paper Size PCB passes signals between the MCU PCB, the Feed PCB and Trays 2 and 3, if installed.The Paper Size Switches that are used to detect the current paper size in the tray are also installed on thisPCB.
Registration Clutch - ElectricThe Registration Clutch - Electric activates the registration rollers after the Registration sensor detects thepaper.
Registration SensorThe Registration Sensor detects when the paper has successfully entered the registration rollers from thetray.
ROS Asm (Laser)The ROS Asm contains a laser that produces a light to expose areas on the drum inside the TonerCartridge. The drum then attracts toner onto the areas the laser has exposed, which is later transferred tothe paper.
Toner CartridgeThe Toner Cartridge is a customer-replaceable unit that contains the toner and drum.
Toner Cartridge Key SensorThe Toner Cartridge Key Sensor detects if an IBM Toner Cartridge is installed. If a non-IBM Toner Cartridgeis installed, the sensor will not recognize the cartridge.
Toner Sensor AsmThe Toner Sensor is a magnetic sensor used to detect a low toner condition in the Toner Cartridge. Once alow toner condition is detected, the Toner Cartridge should be replaced or print quality will severly degrade(lighten).
Tray Lift MotorThe Tray Lift Motor is used to raise the tray’s paper supply until contact is made with the pick rollers.
Appendix C. Parts Theory 622
IBMR
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