Hp Laserjet Cp5000 Cp5525Dn Laser Printer Ce708A201 Users Manual Color Enterprise CP5520 Series Service

2015-02-11

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HP COLOR LASERJET ENTERPRISE CP5520
PRINTER SERIES
Service Manual
HP Color LaserJet Enterprise CP5520
Printer Series
Service Manual
Copyright and License
© 2010 Copyright Hewlett-Packard
Development Company, L.P.
Reproduction, adaptation, or translation
without prior written permission is
prohibited, except as allowed under the
copyright laws.
The information contained herein is subject
to change without notice.
The only warranties for HP products and
services are set forth in the express warranty
statements accompanying such products and
services. Nothing herein should be
construed as constituting an additional
warranty. HP shall not be liable for technical
or editorial errors or omissions contained
herein.
Part number: CE707-90935
Edition 1, 11/2010
Trademark Credits
Adobe
®
, Acrobat
®
, and PostScript
®
are
trademarks of Adobe Systems Incorporated.
Corel® is a trademark or registered
trademark of Corel Corporation or Corel
Corporation Limited.
Microsoft®, Windows®, Windows® XP,
and Windows Vista® are U.S. registered
trademarks of Microsoft Corporation.
UNIX
®
is a registered trademark of The
Open Group.
ENERGY STAR
®
and the ENERGY STAR
®
mark are registered U.S. marks.
Conventions used in this guide
TIP: Tips provide helpful hints or shortcuts.
NOTE: Notes provide important information to explain a concept or to complete a task.
CAUTION: Cautions indicate procedures that you should follow to avoid losing data or damaging
the product.
WARNING! Warnings alert you to specific procedures that you should follow to avoid personal
injury, catastrophic loss of data, or extensive damage to the product.
ENWW iii
iv Conventions used in this guide ENWW
Table of contents
1 Theory of operation .......................................................................................................... 1
Basic operation ........................................................................................................................ 2
Major product systems ............................................................................................... 2
Product block diagram ............................................................................................... 2
Sequence of operation ............................................................................................... 3
Normal sequence of operation ..................................................................... 3
Formatter-control system ............................................................................................................ 5
Sleep mode .............................................................................................................. 5
Input/output ............................................................................................................. 6
CPU ........................................................................................................................ 6
Memory ................................................................................................................... 6
Firmware ................................................................................................... 6
Nonvolatile memory ................................................................................... 6
PJL overview ............................................................................................................. 6
PML ......................................................................................................................... 7
Control panel ........................................................................................................... 7
Engine-control system ................................................................................................................ 8
DC controller ............................................................................................................ 9
Motors .................................................................................................... 12
Fans ....................................................................................................... 14
Fuser-control circuit ................................................................................... 15
Fuser temperature control ........................................................... 16
Fuser protective function ............................................................. 17
Fuser failure detection ................................................................ 18
Low-voltage power supply ......................................................................... 19
Overcurrent/overvoltage protection ............................................. 21
High-voltage power supply ........................................................................ 22
Laser scanner system ............................................................................................... 24
Laser failure detection ............................................................................... 25
Image-formation system ........................................................................................................... 26
Electrophotographic process ..................................................................................... 26
Image formation process .......................................................................................... 28
ENWW v
Latent-image formation block ..................................................................... 29
Pre-exposure ............................................................................. 29
Primary charging ...................................................................... 29
Laser beam exposure ................................................................. 30
Developing block ..................................................................................... 31
Transfer block .......................................................................................... 32
Primary transfer ......................................................................... 32
Secondary transfer .................................................................... 32
Separation ............................................................................... 33
Fusing block ............................................................................................ 33
ITB cleaning block .................................................................................... 34
Drum cleaning block ................................................................................. 34
Print cartridges ........................................................................................................ 35
Memory tag ............................................................................................ 36
Cartridge presence detection ..................................................................... 36
Toner level detection ................................................................................. 36
Cartridge life detection ............................................................................. 36
Developing unit engagement and disengagement control .............................. 36
ITB unit .................................................................................................................. 38
Primary transfer roller engagement and disengagement control ...................... 39
ITB unit presence detection ........................................................................ 40
ITB cleaning mechanism ............................................................................ 40
Calibration ............................................................................................................. 41
Color-misregistration control ...................................................................... 42
Environment change control ....................................................................... 43
Image stabilization control ........................................................................ 43
Image density control (DMAX) ..................................................... 43
Image halftone control (DHALF) ................................................... 43
Pickup, feed, and delivery system ............................................................................................. 44
Photo sensors .......................................................................................................... 46
Motors and solenoids .............................................................................................. 47
Pickup and feed block ............................................................................................. 47
Tray 2 cassette pickup .............................................................................. 48
Tray 2 cassette multiple-feed prevention ...................................................... 49
Tray 2 cassette media-size detection and Tray 2 cassette-presence detection .. . 50
Tray 2 cassette lift-up operation .................................................................. 51
Cassette media-presence detection ............................................................. 53
Tray 1 (MP tray) paper pickup .................................................................................. 53
Tray 1 (MP tray) last-paper detection ......................................................................... 54
Paper feed ............................................................................................................. 55
Skew-feed prevention ................................................................................ 57
vi ENWW
Media detection ....................................................................................... 58
Feed-speed control ................................................................................... 59
Fusing and delivery block ......................................................................................... 59
Loop control ............................................................................................ 59
Pressure roller pressurization and depressurization control ............................ 61
Output bin full detection ............................................................................ 62
Duplex block (duplex models only) ............................................................................ 63
Duplex reverse and duplex feed control ...................................................... 63
Duplex operation ..................................................................................... 64
Jam detection ......................................................................................................... 66
Paper feeder ......................................................................................................................... 68
Paper-feeder motors ................................................................................................. 69
Paper-feeder paper pickup and feed ......................................................................... 70
Cassette media-size detection and cassette-presence detection ...................................... 70
Paper-feeder cassette lift operation ............................................................................ 71
Paper-feeder jam detection ....................................................................................... 72
Optional 3X500-sheet paper deck ........................................................................................... 73
Motor control .......................................................................................................... 76
Pickup-and-feed operation ........................................................................................ 77
Cassette media-size detection and cassette-presence detection ...................................... 78
Cassette lift-up operation .......................................................................................... 79
Jam detection ......................................................................................................... 81
2 Removal and replacement .............................................................................................. 83
Introduction ........................................................................................................................... 84
Removal and replacement strategy ........................................................................................... 84
Electrostatic discharge ............................................................................................................ 84
Required tools ........................................................................................................................ 85
Service approach ................................................................................................................... 86
Before performing service ........................................................................................ 86
After performing service ........................................................................................... 86
Post-service test ....................................................................................................... 86
Print-quality test ........................................................................................ 86
Removal and replacement procedures ...................................................................................... 87
Print cartridges ........................................................................................................ 87
Toner-collection unit ................................................................................................. 91
Fuser ..................................................................................................................... 93
Reset the New Fuser Kit setting at the control panel ...................................... 93
Pickup roller (Tray 1) ............................................................................................... 94
Separation pad (Tray 1) ........................................................................................... 95
Separation roller assembly (Tray 2) ........................................................................... 97
ENWW vii
Pickup roller (Tray 2) ............................................................................................... 98
Pickup roller, separation roller, and feed roller (1 x 500-sheet and 3 x 500-sheet paper
feeders) ................................................................................................................. 99
Secondary transfer roller ........................................................................................ 101
Intermediate transfer belt (ITB) ................................................................................. 102
Reset the New Transfer Kit setting at the control panel ................................ 104
Formatter PCA ...................................................................................................... 105
Hard Drive ........................................................................................................... 107
Remove the encrypted HDD ..................................................................... 108
Remove the solid-state hard drive ............................................................. 109
Covers ................................................................................................................. 111
Identification and location ....................................................................... 111
Right-front cover and control-panel assembly .............................................. 113
Left cover .............................................................................................. 115
Rear cover ............................................................................................. 116
Remove the rear cover ............................................................. 116
Toner collection unit access door .............................................................. 117
Right-rear cover ...................................................................................... 119
Reinstall the right-rear cover ...................................................... 120
Top cover .............................................................................................. 121
Remove the top cover .............................................................. 121
Front-door assembly ............................................................................... 123
Right-door assembly ............................................................................... 126
Main assemblies ................................................................................................... 130
Formatter case ....................................................................................... 130
Remove the formatter case ........................................................ 130
Laser/scanner assembly .......................................................................... 132
Remove the laser/scanner assembly .......................................... 132
Paper pickup assembly ........................................................................... 135
Remove the paper pickup assembly ........................................... 135
Reinstall the paper pickup assembly .......................................... 138
Registration sensor assembly ................................................................... 142
Remove the registration sensor assembly .................................... 142
Lifter-drive assembly ................................................................................ 145
Remove the lifter-drive assembly ................................................ 145
ITB front guide assembly ......................................................................... 148
ITB rear guide assembly .......................................................................... 151
Residual toner full sensor ......................................................................... 152
Remove the residual toner full sensor ......................................... 152
Main drive assembly .............................................................................. 157
Remove the main drive assembly ............................................... 157
viii ENWW
Install the main drive assembly .................................................. 167
Fuser drive assembly .............................................................................. 172
Remove the fuser drive assembly ............................................... 172
Install a replacement fuser drive assembly .................................. 174
Fuser gear assembly ............................................................................... 176
Remove the fuser gear assembly ................................................ 176
Install a replacement fuser gear assembly ................................... 182
Paper delivery assembly .......................................................................... 184
Remove the delivery assembly ................................................... 184
Reinstall the paper delivery assembly ......................................... 185
Duplex drive assembly (duplex models) ..................................................... 187
Remove the duplex-drive assembly ............................................. 187
Delivery drive assembly (simplex models) .................................................. 189
Remove the delivery drive assembly ........................................... 189
Residual-toner-feed assembly ................................................................... 190
Remove the residual-toner-feed assembly .................................... 190
ITB motor (M1) ....................................................................................... 192
Remove the ITB motor .............................................................. 192
Drum motor (M2) ................................................................................... 194
Remove the drum motor ........................................................... 194
Developing motor (M3) ........................................................................... 195
Remove the developing motor ................................................... 195
Fuser motor (M4) .................................................................................... 196
Remove the fuser motor ............................................................ 196
Developing-disengagement motor (M6) ..................................................... 197
Remove the developing-disengagement motor ............................. 197
Power-supply fan (FM1) .......................................................................... 198
Remove the power-supply fan ................................................... 198
Fuser fan (FM2) ...................................................................................... 201
Remove the fuser fan ............................................................... 201
Formatter fan (FM3) and ICB PCA ............................................................ 204
Remove the formatter fan and ICB PCA ...................................... 204
DC controller PCA .................................................................................. 207
Remove the DC controller PCA .................................................. 207
Low-voltage power supply ....................................................................... 209
Remove the low-voltage power supply ........................................ 209
Imaging (developing) high-voltage power supply ........................................ 213
Remove the imaging (developing) high-voltage power supply ....... 213
First transfer high-voltage power supply ..................................................... 214
Remove the first transfer high-voltage power supply ..................... 214
Second transfer high-voltage power supply ................................................ 216
ENWW ix
Remove the second transfer high-voltage power supply ................ 216
Driver PCA ............................................................................................ 218
Remove the driver PCA ............................................................ 218
Power switch PCA .................................................................................. 220
Remove the power switch PCA .................................................. 220
Environmental sensor .............................................................................. 221
Remove the environmental sensor .............................................. 221
1 x 500-sheet paper feeder assembly ...................................................................... 222
1 x 500 rear cover ................................................................................. 222
1 x 500 left cover .................................................................................. 223
1 x 500 right-front cover ......................................................................... 225
1 x 500 front-upper cover ....................................................................... 226
1 x 500 right door ................................................................................. 227
1 x 500 right-lower cover ........................................................................ 229
1 x 500 pickup assembly ........................................................................ 230
1 x 500 lifter-drive assembly ................................................................... 233
1 x 500 pickup motor ............................................................................. 234
1 x 500 driver PCA ................................................................................ 235
3 x 500-sheet paper feeder (optional accessory) ....................................................... 236
3 x 500 rear cover ................................................................................. 236
3 x 500 right and left cassette rails .......................................................... 237
3 x 500 paper deck controller PCAs ........................................................ 238
3 x 500 paper deck lifter-drive assembly .................................................. 239
3 x 500 paper deck pickup motor ............................................................ 240
3 x 500 front-lower cover ........................................................................ 241
3 x 500 left cover .................................................................................. 242
3 x 500 right-corner cover ...................................................................... 243
3 x 500 front-upper cover ....................................................................... 244
3 x 500 right-door assembly .................................................................... 245
3 x 500 right-lower cover 1 ..................................................................... 247
3 x 500 right-lower cover 2 ..................................................................... 248
3 x 500 left-lower cover .......................................................................... 249
3 x 500 rear-lower cover ........................................................................ 250
Remove the 3 x 500 rear-lower cover ........................................ 250
3 x 500 paper deck pickup assembly ....................................................... 251
Remove the 3 x 500 paper deck pickup assembly ....................... 251
3 Solve problems ............................................................................................................. 253
Solve problems checklist ....................................................................................................... 254
Menu map .......................................................................................................................... 256
Current settings pages ........................................................................................... 256
xENWW
Control panel menus .............................................................................................. 257
Sign In menu ........................................................................................................ 257
Retrieve Job From USB menu .................................................................................. 257
Retrieve Job From Device Memory menu .................................................................. 257
Supplies menu ...................................................................................................... 258
Trays menu ........................................................................................................... 260
Administration menu .............................................................................................. 261
Reports menu ......................................................................................... 261
General Settings menu ............................................................................ 261
Retrieve From USB Settings menu ............................................................. 266
Print Settings menu ................................................................................. 266
Print Options menu ................................................................................. 267
Display Settings menu ............................................................................. 269
Manage Supplies menu .......................................................................... 270
Manage Trays menu ............................................................................... 271
Network Settings menu ........................................................................... 272
Troubleshooting menu ............................................................................................ 275
Device Maintenance menu ..................................................................................... 276
Backup/Restore menu ............................................................................. 276
Calibration/Cleaning menu ..................................................................... 277
USB Firmware Upgrade menu .................................................................. 277
Service menu ......................................................................................... 278
Troubleshooting process ........................................................................................................ 279
Determine the problem source ................................................................................. 279
Pre-troubleshooting checklist .................................................................... 279
Troubleshooting flowchart ....................................................................... 280
Power subsystem ................................................................................................... 282
Power-on checks .................................................................................... 282
Power-on troubleshooting overview ............................................ 282
Tools for troubleshooting ....................................................................................................... 284
Component diagnostics .......................................................................................... 284
LED diagnostics ...................................................................................... 284
Understand lights on the formatter ............................................. 284
Engine diagnostics ................................................................................. 285
Defeating interlocks ................................................................. 286
Disable cartridge check ........................................................... 287
Engine test button .................................................................... 288
Paper-path test ....................................................................................... 288
Manual sensor test ................................................................................. 289
Front-door opening/closing switch (PS14) .................................. 291
Right-door opening/closing sensor (PS15) .................................. 292
ENWW xi
TOP (top-of-page) sensor (PS5) .................................................. 294
Fuser loop sensors 1 and 2 (PS7 and PS8) ................................. 295
Fuser pressure-release sensor (PS9) ............................................ 296
Fuser output sensor (PS6) .......................................................... 297
Developer alienation sensor (PS11) ........................................... 298
ITB alienation switch (SW5) ...................................................... 299
Tray/Bin manual sensor test .................................................................... 300
Tray 1 paper sensor (PS2) ........................................................ 302
Tray 2 paper present sensor (PS1) ............................................. 303
Tray 2 paper surface sensor (PS4) ............................................. 304
Tray 2 paper size switches (SW7 and SW8) .............................. 305
Tray 3 paper sensor (SR3) ........................................................ 306
Tray 3 paper surface sensor (SR2) ............................................. 307
Tray 3 paper size sensors (SW2 and SW3) ............................... 308
Tray 3 feed sensor (SR1) .......................................................... 309
Tray 3 door opening/closing sensor (SW1) ................................ 310
Tray 4 paper sensor (SR3) ........................................................ 311
Tray 4 paper surface sensor (SR2) ............................................. 311
Tray 4 paper size sensors (SW2 and SW3) ............................... 311
Tray 4 feed sensor (SR1) .......................................................... 311
Tray 4 door opening/closing door sensor (SW1) ........................ 311
Tray 5 paper sensor (SR83) ...................................................... 312
Tray 5 paper surface sensor (SR82) ........................................... 312
Tray 5 paper size sensors (SW82 and SW83) ........................... 312
Tray 5 feed sensor (SR81) ........................................................ 312
Tray 5 door opening/closing sensor (SW1) ................................ 312
Tray 6 paper sensor (SR93) ...................................................... 312
Tray 6 paper surface sensor (SR92) ........................................... 312
Tray 6 paper size sensors (SW92 and SW93) ........................... 312
Tray 6 feed sensor (SR91) ........................................................ 312
Tray 6 door opening/closing sensor (SW1) ................................ 312
Output-bin-full sensor (PS10) ..................................................... 313
Paper-path sensors test ............................................................................ 313
Print/stop test ........................................................................................ 314
Component tests ..................................................................................... 314
Component test (special-mode test) ............................................ 314
Additional component tests ....................................................... 317
Diagrams ............................................................................................................. 319
Block diagrams ...................................................................................... 319
Plug/jack locations ................................................................................. 321
Location of connectors ............................................................................ 322
xii ENWW
DC controller connections ......................................................... 322
Product connections ................................................................. 324
Locations of major components ................................................................ 331
General timing charts ............................................................................. 338
General circuit diagram .......................................................................... 340
Internal print-quality test pages ................................................................................ 344
Print-quality-troubleshooting pages ............................................................ 344
Diagnostics page ................................................................................... 347
Clean the paper path ............................................................................. 349
Set up an auto cleaning page ................................................... 349
Configuration page ................................................................................ 350
Configuration page ................................................................. 350
HP embedded Jetdirect page .................................................... 352
Finding important information on the configuration pages ............ 353
Color-band test ...................................................................................... 354
Print quality troubleshooting tools ............................................................................ 355
Repetitive image-defect ruler .................................................................... 355
Calibrate the product .............................................................................. 356
Control panel menus .............................................................................................. 356
Sign In menu ......................................................................................... 357
Retrieve Job From USB menu ................................................................... 358
Retrieve Job From Device Memory menu ................................................... 359
Supplies menu ....................................................................................... 360
Trays menu ............................................................................................ 363
Administration menu ............................................................................... 365
Reports menu .......................................................................... 365
General Settings menu ............................................................. 367
Retrieve From USB Settings menu .............................................. 380
Print Settings menu .................................................................. 380
Print Options menu .................................................................. 382
Display Settings menu .............................................................. 384
Manage Supplies menu ........................................................... 385
Manage Trays menu ................................................................ 388
Network Settings menu ............................................................ 391
Troubleshooting menu ............................................................................. 401
Device Maintenance menu ...................................................................... 406
Backup/Restore menu .............................................................. 406
Calibration/Cleaning menu ...................................................... 407
USB Firmware Upgrade menu ................................................... 408
Service menu .......................................................................... 409
Interpret control-panel messages, status-alert messages, and event code errors .............. 411
ENWW xiii
10.0X.Y0 Supply memory error ............................................................... 411
10.22.50 .............................................................................................. 412
10.22.51 .............................................................................................. 412
10.22.52 .............................................................................................. 412
10.23.50 .............................................................................................. 412
10.23.51 .............................................................................................. 413
10.23.52 .............................................................................................. 413
10.23.70 Printing past very low .............................................................. 413
10.XX.34 Used supply in use ................................................................... 414
10.XX.40 Genuine HP supplies installed ................................................... 414
10.XX.41 Unsupported supply in use ........................................................ 415
10.XX.70 Printing past very low ............................................................... 415
10.YY.15 Install <supply> ....................................................................... 416
10.YY.25 Wrong cartridge in <color> slot ................................................ 416
10.YY.35 Incompatible <supply> ............................................................. 417
11.00.YY Internal clock error .................................................................. 418
13.00.00 .............................................................................................. 418
13.A3.FF .............................................................................................. 418
13.D3.DZ ............................................................................................. 418
13.WX.EE ............................................................................................. 419
13.WX.FF ............................................................................................. 419
13.WX.YZ Fuser area jam ...................................................................... 420
13.WX.YZ Fuser wrap jam ...................................................................... 421
13.WX.YZ Jam below control panel ......................................................... 422
13.WX.YZ Jam in lower right door ........................................................... 422
13.WX.YZ Jam in middle right door ......................................................... 423
13.WX.YZ Jam in right door .................................................................... 423
13.WX.YZ Jam in Tray 1 ........................................................................ 424
13.WX.YZ Jam in Tray <X> ..................................................................... 424
20.00.00 Insufficient memory To continue, press OK .................................. 425
21.00.00 Page too complex ................................................................... 425
32.1C.XX .............................................................................................. 425
32.21.00 .............................................................................................. 430
40.00.01 USB I/O buffer overflow To continue, press OK .......................... 430
40.00.02 Embedded I/O buffer overflow To continue, press OK ................. 430
40.00.03 EIO buffer overflow To continue, press OK ................................. 430
40.00.04 Unsupported USB accessory detected To continue, press OK ........ 430
40.00.05 Embedded I/O bad transmission To continue, press OK .............. 431
41.02.00 Error ...................................................................................... 431
41.03.YZ Unexpected size in tray <X> ..................................................... 431
41.05.YZ Unexpected type in tray <X> .................................................... 432
xiv ENWW
41.07.YZ Error To continue, press OK ...................................................... 434
42.XX.YY .............................................................................................. 436
47.00.XX .............................................................................................. 436
47.01.XX .............................................................................................. 436
47.02.XX .............................................................................................. 436
47.03.XX .............................................................................................. 437
47.04.XX .............................................................................................. 437
47.05.00 .............................................................................................. 437
47.06.XX .............................................................................................. 437
47.WX.YZ Printer calibration error To continue, press OK ........................... 437
50.WX.YZ Fuser error To continue, turn off then on .................................... 439
51.00.YY Error ...................................................................................... 442
52.XX.00 Error To continue, turn off then on .............................................. 442
54.XX.YY Error ...................................................................................... 443
55.00.YY DC controller error To continue, turn off then on .......................... 445
55.0X.YY DC controller error To continue, turn off then on .......................... 446
56.00.YY Error To continue, turn off then on .............................................. 446
57.00.0Y Error To continue, turn off then on ............................................. 446
59.00.YY Error To continue, turn off then on .............................................. 447
59.0X.50 Error To continue, turn off then on .............................................. 448
59.0X.60 Error To continue, turn off then on .............................................. 449
59.0X.70 Error To continue, turn off then on .............................................. 449
59.0X.80 Error To continue, turn off then on .............................................. 449
60.00.0Y Tray <Y> lifting error ............................................................... 450
61.00.01 .............................................................................................. 451
62.00.00 No system To continue, turn off then on ...................................... 452
70.00.00 Error To continue, turn off then on ............................................. 452
80.0X.YY Embedded JetDirect error ......................................................... 452
98.00.01 Corrupt data in firmware volume ............................................... 454
98.00.02 Corrupt data in solutions volume ............................................... 454
98.00.03 Corrupt data in configuration volume ......................................... 454
98.00.04 Corrupt data in job data volume ............................................... 454
99.00.01 Upgrade not performed file is corrupt ........................................ 455
99.00.02 Upgrade not performed timeout during receive ........................... 455
99.00.03 Upgrade not performed error writing to disk ............................... 455
99.00.04 Upgrade not performed timeout during receive ........................... 455
99.00.05 Upgrade not performed timeout during receive ........................... 456
99.00.06 Upgrade not performed error reading upgrade ........................... 456
99.00.07 Upgrade not performed error reading upgrade ........................... 456
99.00.08 Upgrade not performed error reading upgrade ........................... 456
99.00.09 Upgrade canceled by user ....................................................... 457
ENWW xv
99.00.10 Upgrade canceled by user ....................................................... 457
99.00.11 Upgrade canceled by user ....................................................... 457
99.00.12 Upgrade not performed the file is invalid ................................... 457
99.00.13 Upgrade not performed the file is invalid ................................... 458
99.00.14 Upgrade not performed the file is invalid ................................... 458
99.00.2X .............................................................................................. 458
99.09.60 Unsupported disk .................................................................... 459
99.09.61 Unsupported disk .................................................................... 459
99.09.62 Unknown disk ......................................................................... 459
99.09.63 Incorrect disk .......................................................................... 460
99.09.64 Disk malfunction ...................................................................... 460
99.09.65 Disk data error ........................................................................ 460
99.09.66 No disk data installed .............................................................. 460
99.09.67 Disk is not bootable please download firmware .......................... 460
99.XX.YY .............................................................................................. 461
<Binname> Full Remove all paper from bin ............................................... 461
<Supply> almost full ............................................................................... 461
<Supply> low OR Supplies low ................................................................ 461
<Supply>very low OR Supplies very low ................................................... 462
<Tray X> lifting ...................................................................................... 463
[File System] device failure To clear, press OK ........................................... 464
[File System] file operation failed To clear, press OK .................................. 464
[File System] file system is full To clear, press OK ....................................... 464
[File System] is not initialized ................................................................... 464
[File System] is write protected ................................................................. 464
Accept bad signature ............................................................................. 464
Bad optional tray connection ................................................................... 465
Calibration reset pending ........................................................................ 465
Canceling ............................................................................................. 465
Canceling... <jobname> ......................................................................... 465
Checking engine .................................................................................... 466
Checking paper path .............................................................................. 466
Chosen personality not available To continue, press OK ............................. 466
Cleaning do not grab paper .................................................................... 466
Cleaning... ............................................................................................ 466
Clearing event log .................................................................................. 467
Clearing paper path ............................................................................... 467
Close front door ..................................................................................... 467
Close lower right door ............................................................................ 467
Close middle right door .......................................................................... 468
Close right door ..................................................................................... 468
xvi ENWW
Close upper right door For help press ? .................................................... 468
Cooling device ...................................................................................... 468
Creating cleaning page .......................................................................... 469
Data received To print last page, press OK ............................................... 469
EIO <X> disk initializing ......................................................................... 469
EIO <X> disk not functional ..................................................................... 469
EIO <X> disk spinning up ....................................................................... 470
Event log is empty .................................................................................. 470
Expected drive missing ........................................................................... 470
HP Secure Hard Drive disabled ................................................................ 470
Incompatible <supply> ............................................................................ 471
Incompatible supplies ............................................................................. 471
Initializing... .......................................................................................... 471
Install <supply> ...................................................................................... 472
Install <supply> Close rear door .............................................................. 472
Install Fuser Unit ..................................................................................... 472
Install supplies ....................................................................................... 473
Install Transfer Unit ................................................................................. 473
Internal disk not functional ....................................................................... 473
Internal disk spinning up ......................................................................... 474
Load Tray <X>: [Type], [Size] .................................................................. 474
Load Tray <X>: [Type], [Size] To use another tray, press OK ....................... 475
Loading program <XX> Do not power off .................................................. 475
Manually feed output stack Then press OK to print second sides .................. 475
Manually feed: [Type], [Size] ................................................................... 475
Manually feed: [Type], [Size] To use another tray, press OK ....................... 476
Moving solenoid .................................................................................... 476
Moving solenoid and motor ..................................................................... 476
No job to cancel .................................................................................... 476
Paused .................................................................................................. 477
Performing Color Band Test... .................................................................. 477
Performing Paper Path Test... ................................................................... 477
Please wait... ......................................................................................... 477
Printing CMYK samples... ........................................................................ 477
Printing Color Usage Log... ..................................................................... 478
Printing Configuration... .......................................................................... 478
Printing Demo Page... ............................................................................. 478
Printing Diagnostics Page... ..................................................................... 478
Printing Engine Test... ............................................................................. 478
Printing Event Log... ................................................................................ 478
Printing File Directory... ........................................................................... 479
ENWW xvii
Printing Font List... .................................................................................. 479
Printing Fuser Test Page... ....................................................................... 479
Printing Help Page... .............................................................................. 479
Printing Menu Map... ............................................................................. 479
Printing PQ Troubleshooting... ................................................................. 480
Printing Registration Page... ..................................................................... 480
Printing RGB Samples... .......................................................................... 480
Printing stopped ..................................................................................... 480
Printing Supplies Status Page... ................................................................ 480
Printing Usage Page... ............................................................................ 480
Processing duplex job Do not grab paper until job completes ...................... 481
Processing job from tray <X>... Do not grab paper until job completes ......... 481
Processing... <filename> ......................................................................... 481
Processing... copy <X> of <Y> ................................................................ 481
Ready ................................................................................................... 482
Ready <IP Address> ............................................................................... 482
Remove all print cartridges ...................................................................... 482
Remove at least one print cartridge .......................................................... 482
Remove shipping lock from Tray 2 ............................................................ 482
Replace <supply> .................................................................................. 483
Replace supplies .................................................................................... 484
Restore Factory Settings .......................................................................... 484
Restricted from printing in color ................................................................ 485
Rotating <color> motor ........................................................................... 485
Rotating motor ....................................................................................... 485
Size mismatch in Tray <X> ...................................................................... 485
Sleep mode on ...................................................................................... 486
Supplies in wrong positions ..................................................................... 486
Tray <X> empty: [Type], [Size] ................................................................ 486
Tray <X> open ....................................................................................... 487
Tray <X> overfilled ................................................................................. 488
Troubleshooting ..................................................................................... 488
Type mismatch Tray <X> ......................................................................... 488
Unsupported drive installed To continue, press OK ..................................... 489
Unsupported supply in use OR Unsupported supply installed To continue,
press OK ............................................................................................... 489
Unsupported tray configuration ................................................................ 490
Unsupported USB accessory detected Remove USB accessory ...................... 490
USB accessory needs too much power Remove USB and turn off then on ...... 490
USB accessory not functional ................................................................... 490
Used supply installed To continue, press OK OR Used supply in use ............. 491
xviii ENWW
Wrong cartridge in <color> slot ............................................................... 491
Event-log messages ............................................................................................... 492
Print an event log ................................................................................... 493
View an event log .................................................................................. 493
Clear an event log .................................................................................. 494
Clear jams .......................................................................................................................... 495
Common causes of jams ........................................................................................ 495
Jam locations ........................................................................................................ 496
Clear jams in the upper-right door ........................................................................... 501
Clear jams in the lower-right door ........................................................................... 503
Clear jams in Tray 1 .............................................................................................. 504
Clear jams from Tray 2, Tray 3, or an optional tray .................................................. 506
Clear jams in the output bin area ............................................................................ 507
Jam causes and solutions ....................................................................................... 508
Jams in the output bin ............................................................................. 508
Jams in the fuser and transfer area ........................................................... 508
Jams in the duplex area (duplex models only) ............................................ 509
Jams in Tray 1, Tray 2 and internal paper path .......................................... 510
Jams in Tray 3, 4, 5, and 6 ..................................................................... 513
Change jam recovery ............................................................................................ 515
Solve paper-handling problems .............................................................................................. 516
Product feeds multiple sheets .................................................................................. 516
Product feeds incorrect page size ............................................................................ 516
Product pulls from incorrect tray .............................................................................. 517
Paper does not feed automatically ........................................................................... 517
Paper does not feed from Tray 2, 3, 4, 5, or 6 ......................................................... 517
Transparencies or glossy paper will not feed ............................................................ 518
Envelopes jam or will not feed in the product ............................................................ 519
Output is curled or wrinkled ................................................................................... 519
Product will not duplex or duplexes incorrectly .......................................................... 520
Use manual print modes ....................................................................................................... 521
Solve image-quality problems ................................................................................................ 524
Print quality examples ............................................................................................ 524
Clean the product ................................................................................................................ 531
Clean the paper path ............................................................................................ 531
Set up an auto cleaning page .................................................................. 531
Solve performance problems ................................................................................................. 532
Solve connectivity problems ................................................................................................... 533
Solve direct-connect problems ................................................................................. 533
Solve network problems ......................................................................................... 533
Service mode functions ......................................................................................................... 534
ENWW xix
Service menu ........................................................................................................ 534
Product resets ....................................................................................................... 536
Restore factory-set defaults ....................................................................... 536
Clean Disk and Partial Clean functions .................................................................... 537
Active and repository firmware locations ................................................... 537
Partial Clean ......................................................................................... 537
Execute a Partial Clean ............................................................ 538
Clean Disk ............................................................................................ 538
Execute a Clean Disk ............................................................... 539
Preboot menu options ........................................................................................................... 540
Product updates ................................................................................................................... 547
Determine the installed revision of firmware .............................................................. 547
Perform a firmware upgrade ................................................................................... 547
Embedded Web Server ........................................................................... 547
USB storage device (Preboot menu) .......................................................... 548
USB storage device (control-panel menu) ................................................... 549
4 Parts and diagrams ...................................................................................................... 551
Order parts by authorized service providers ............................................................................ 552
Order parts, accessories, and supplies .................................................................... 552
Related documentation and software ....................................................................... 552
Supplies part numbers ........................................................................................... 553
Customer self repair parts ...................................................................................... 553
Service replacement parts ...................................................................................... 555
Accessories part numbers ....................................................................................... 557
How to use the parts lists and diagrams .................................................................................. 558
Assembly locations ............................................................................................................... 559
External covers, panels, and doors ......................................................................................... 560
Right door assembly ............................................................................................................. 562
Internal components (1 of 9) .................................................................................................. 564
Internal components (2 of 9) .................................................................................................. 566
Internal components (3 of 9) .................................................................................................. 568
Internal components (4 of 9) .................................................................................................. 570
Internal components (5 of 9) .................................................................................................. 572
Internal components (6 of 9) .................................................................................................. 574
Internal components (7 of 9) .................................................................................................. 576
Internal components (8 of 9) .................................................................................................. 578
Internal components (9 of 9) .................................................................................................. 580
1x250 cassette .................................................................................................................... 582
Paper pick-up assembly ........................................................................................................ 584
Paper delivery assembly ....................................................................................................... 586
xx ENWW
Printed circuit assemblies ...................................................................................................... 588
1x500 paper feeder ............................................................................................................. 590
1x500PF external components ................................................................................ 590
1x500PF internal components ................................................................................. 592
1x500PF PCA ....................................................................................................... 594
3x500 paper feeder ............................................................................................................. 596
3x500PF external components ................................................................................ 596
3x500PF internal components ................................................................................. 598
3x500PF cassette .................................................................................................. 600
3x500PF PCAs ..................................................................................................... 602
Alphabetical parts list ........................................................................................................... 604
Numerical parts list .............................................................................................................. 617
Appendix A Service and support ..................................................................................... 631
Hewlett-Packard limited warranty statement ............................................................................. 632
HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement .................. 633
Color LaserJet Fuser Kit, Transfer Kit, and Toner Collection Unit Limited Warranty Statement .......... 634
Data stored on the print cartridge ........................................................................................... 635
End User License Agreement .................................................................................................. 636
Customer self-repair warranty service ..................................................................................... 638
Customer support ................................................................................................................. 639
Appendix B Product specifications ................................................................................... 641
Physical specifications .......................................................................................................... 642
Power consumption, electrical specifications, and acoustic emissions .......................................... 642
Environmental specifications .................................................................................................. 642
Appendix C Regulatory information ................................................................................. 643
FCC regulations ................................................................................................................... 644
Environmental product stewardship program ........................................................................... 645
Protecting the environment ...................................................................................... 645
Ozone production ................................................................................................. 645
Power consumption ............................................................................................... 645
Paper use ............................................................................................................. 645
Plastics ................................................................................................................. 645
HP LaserJet print supplies ....................................................................................... 645
Return and recycling instructions ............................................................................. 646
United States and Puerto Rico .................................................................. 646
Multiple returns (more than one cartridge) .................................. 646
Single returns .......................................................................... 646
ENWW xxi
Shipping ................................................................................ 646
Non-U.S. returns .................................................................................... 646
Paper .................................................................................................................. 647
Material restrictions ............................................................................................... 647
Disposal of waste equipment by users in private households in the European Union ...... 647
Chemical substances ............................................................................................. 648
Material Safety Data Sheet (MSDS) ......................................................................... 648
For more information ............................................................................................. 648
Declaration of Conformity ..................................................................................................... 649
Certificate of Volatility .......................................................................................................... 651
Types of memory ................................................................................................... 651
Volatile memory ..................................................................................... 651
Non-volatile memory .............................................................................. 651
Hard-disk-drive memory .......................................................................... 651
Safety statements ................................................................................................................. 652
Laser safety .......................................................................................................... 652
Canadian DOC regulations .................................................................................... 652
VCCI statement (Japan) .......................................................................................... 652
Power cord instructions .......................................................................................... 652
Power cord statement (Japan) ................................................................................. 652
EMC statement (China) .......................................................................................... 653
EMC statement (Korea) .......................................................................................... 653
EMI statement (Taiwan) .......................................................................................... 653
Laser statement for Finland ..................................................................................... 653
GS statement (Germany) ........................................................................................ 654
Substances Table (China) ....................................................................................... 654
Restriction on Hazardous Substances statement (Turkey) ............................................. 654
Index ............................................................................................................................... 655
xxii ENWW
1 Theory of operation
●Basic operation
●Formatter-control system
●Engine-control system
●Image-formation system
●Pickup, feed, and delivery system
●Paper feeder
●Optional 3X500-sheet paper deck
ENWW 1
Basic operation
Major product systems
The product contains the following five systems:
●Engine-control system
●Laser scanner system
●Image-formation system
●Media feed system
●Optional paper feeder system
Product block diagram
Figure 1-1 Product block diagram
MEDIA FEED SYSTEM
LASER SCANNER SYSTEM
ENGINE CONTROL SYSTEM
IMAGE-FORMATION SYSTEM
OPTION
2 Chapter 1 Theory of operation ENWW
Sequence of operation
The DC controller in the engine-control system controls the operational sequences of the product. The
following table describes durations and operations for each period of a print operation from the time
the product is turned on until the motor stops rotating.
Normal sequence of operation
Table 1-1 Sequence of operation
Name Timing Purpose
WAIT From the time the power switch is turned on, the door
is closed, or the product exits Sleep mode, until the
product is ready for a print operation.
Brings the product to printable condition:
●Detects and heats the fuser
●Detects the print cartridge and any cartridge
changes
●Detects the ITB, and moves the ITB and the
developing unit to the home position
●Cleans residual toner from the intermediate
transfer belt (ITB) and the secondary transfer
roller
STBY (standby) From the end of the WAIT or LSTR period until either
a print command is sent or the power switch is
turned off.
Maintains the product in printable condition:
●Enters Sleep mode if the sleep command is
received
●Performs a calibration if the calibration
command is received
INTR (initial
rotation)
From the time the print command is received until the
product picks up a piece of paper.
Prepares for the print job
●Activates the high-voltage power supply
●Activates the laser scanner
●Opens the laser shutter
●Cleans the protective laser glass
●Engages the print cartridges
●Warms the fuser
ENWW Basic operation 3
Table 1-1 Sequence of operation (continued)
Name Timing Purpose
PRINT From the end of the INTR period until the last sheet
completes the fusing operation.
Prints
●Forms the image on the photosensitive drum
●Transfers the toner image to the paper
●Fuses the toner image to the paper
LSTR (last
rotation)
From the end of the PRINT period until the main
motor stops rotating.
Moves the last printed sheet to the output bin.
●Stops the high-voltage power supply
●Stops the laser scanner
●Closes the laser shutter
●Cleans the protective laser glass
●Disengages the print cartridges
●Stops the fuser
The product enters the INTR period as the LSTR
period is completed, if the formatter sends another
print command.
4 Chapter 1 Theory of operation ENWW
Formatter-control system
The formatter is responsible for the following procedures:
●Controlling sleep mode
●Receiving and processing print data from the various product interfaces
●Monitoring control-panel functions and relaying product-status information (through the control
panel and the network or bidirectional interface)
●Developing and coordinating data placement and timing with the DC controller PCA
●Storing font information
●Communicating with the host computer through the network or the bidirectional interface
The formatter receives a print job from the network or bidirectional interface and separates it into
image information and instructions that control the printing process. The DC controller PCA
synchronizes the image-formation system with the paper-input and -output systems, and then signals the
formatter to send the print-image data.
The formatter also provides the electrical interface and mounting locations for an additional DIMM.
Sleep mode
NOTE: In the Display Settings menu (a sub menu of the Administration menu), this item is
termed Sleep Mode.
This feature conserves power after the product has been idle for an adjustable period of time. When
the product is in Sleep Mode, the control-panel backlight is turned off, but the product retains all
settings, downloaded fonts, and macros. The default setting is for Sleep Mode to be enabled, and the
product enters Sleep Mode after a 15-minute idle time.
The product exits Sleep Mode and enters the warm-up cycle when any of the following events occur:
●A print job, valid data, or a PML or PJL command is received
●A control-panel button is pressed
●A cover is opened
●A paper tray is opened
●The engine-test switch is pressed
NOTE: Product error messages override the Sleep message. The product enters Sleep Mode at the
appropriate time, but the error message continues to appear.
ENWW Formatter-control system 5
Input/output
The product has three I/O interfaces:
●USB 2.0 port for connecting directly to a computer
●Internal 10/100Base-T network port
●Walk-up USB port
CPU
The formatter incorporates a 800 MHz Vermillion processor.
Memory
The random access memory (RAM) on the formatter printed circuit assembly (PCA) contains the page,
I/O buffers, and the font storage area. It stores printing and font information received from the host
system, and can also serve to temporarily store a full page of print-image data before the data is sent to
the print engine.
NOTE: If the product encounters a problem when managing available memory, a clearable warning
message appears on the control-panel display.
Firmware
The firmware is contained in the internal solid state drive (SSD) or hard disk (HD). A remote firmware
upgrade process is used to overwrite and upgrade the firmware on the SSD or HD.
Nonvolatile memory
The product uses nonvolatile memory (NVRAM) to store device and user configuration settings. The
contents of NVRAM are retained when the product is turned off or disconnected.
PJL overview
The printer job language (PJL) is an integral part of configuration, in addition to the standard printer
command language (PCL). With standard cabling, the product can use PJL to perform a variety of
functions.
●Two-way communication with the host computer through a network connection or a USB
connection. The product can inform the host about the control-panel settings which can be
changed from the host.
●Dynamic I/O switching. The product uses this switching to be configured with a host on each I/O.
The product can receive data from more than one I/O simultaneously, until the I/O buffer is full.
This can occur even when the product is offline.
6 Chapter 1 Theory of operation ENWW
●Context-sensitive switching. The product can automatically recognize the personality (PS or PCL) of
each job and configure itself to serve that personality.
●Isolation of print environment settings from one print job to the next. For example, if a print job is
sent to the product in landscape mode, the subsequent print jobs print in landscape mode only if
they are formatted for landscape printing.
PML
The printer management language (PML) allows remote configuration and status read-back through the
I/O ports.
Control panel
The formatter sends and receives product status and command data to and from the control-panel PCA.
ENWW Formatter-control system 7
Engine-control system
The engine-control system coordinates all product functions, according to commands that the formatter
sends. The engine-control system drives the laser/scanner system, the image formation system, and the
pickup/feed/delivery system.
The engine control system contains the following major components:
●DC controller
●Low-voltage power supply
●High-voltage power supply
Figure 1-2 Engine-control system
Formatter
DC controller
Low-voltage power supply
High-voltage power supply
LASER SCANNER SYSTEM
IMAGE-FORMATION SYSTEM
MEDIA FEED SYSTEM
ENGINE CONTROL SYSTEM
OPTION
8 Chapter 1 Theory of operation ENWW
DC controller
The DC controller controls the operational sequence of the product.
Figure 1-3 DC controller diagram
Fan
Control panel
Switch
ITB ass’y
Cartridge
(x4)
Transfer 2 high-
voltage
power supply
T2 roller
Fuser
DC controller
AC input
Low-voltage
power supply
Formatter Laser scanner ass’y
Motor
Solenoid
Photointerrupter
Switch
Fan
Accessor y
Sensor
LED
Transfer 1 high-
voltage
power supply
Developing high-
voltage
power supply
Fan
ICB
The DC controller controls the product's electrical components, listed in the following table.
ENWW Engine-control system 9
Table 1-2 Electrical components
Component type Abbreviation Name
Switch SW1 Power switch
SW2 24V interlock switch
SW3 5V interlock switch 1
SW4 5V interlock switch 2
SW5 Primary transfer disengagement switch
SW6 Toner collection unit switch
SW7 Tray 2 cassette media end guide position switch
SW8 Tray 2 cassette media width guide position switch
Solenoid SL1 Tray 2 cassette pickup solenoid
SL2 Tray 1 pickup solenoid
SL3 Duplex reverse solenoid 1 (duplex models only)
SL5 Primary transfer disengagement solenoid
SL7 Duplex reverse solenoid 2 (duplex models only)
Fan FM1 Power supply fan
FM2 Fuser fan
FM3 Formatter fan
Photointerrupter (sensor) PS1 Tray 2 cassette paper-presence sensor
PS2 Tray 1 paper-presence sensor
PS3 Last-paper sensor
PS4 Tray 2 cassette paper-stack surface sensor
PS5 Top-of-page (TOP) sensor
PS6 Fuser delivery sensor
PS7 Loop sensor 1
PS8 Loop sensor 2
PS9 Fuser pressure-release sensor
PS10 Output bin full sensor
PS11 Developing disengagement sensor
PS12 Black drum home-position sensor
PS13 YMC drum home-position sensor
PS14 Front door sensor
PS15 Right door sensor
10 Chapter 1 Theory of operation ENWW
Table 1-2 Electrical components (continued)
Component type Abbreviation Name
Motor M1 ITB Motor
M2 Drum motor
M3 Developing motor
M4 Fuser motor
M5 Pickup motor
M6 Developing disengagement motor
M7 Duplex reverse motor (duplex model only)
M8 Duplex feed motor (duplex model only)
M9 Tray 2 cassette lifter motor
M10 Scanner motor
ENWW Engine-control system 11
Motors
The product has ten motors for paper feed and image formation. The DC controller determines there is
a motor failure if a motor does not reach a specified speed within a specified period after motor
startup, or if the rotational speed is outside a specified range for a specified period.`
Figure 1-4 Motors
Pickup motor
Cassette lifter motor
Scanner motor
Fuser motor
Developer disengagement motor
ITB motor
Drum motor
Developer motor
Duplex feed motor (duplex models)
Duplex reverse motor (duplex models)
12 Chapter 1 Theory of operation ENWW
Table 1-3 Motors
Description Components driven Failure
detection
ITB motor (M1) ITB
Black photosensitive drum
Black developing roller
Yes
Drum motor (M2) Yellow, magenta, and cyan photosensitive drums Yes
Developing motor (M3) Yellow, magenta, and cyan developing rollers Yes
Fuser motor (M4) Fuser pressure and delivery rollers
Pressurizes and depressurizes the pressure roller
Engages and disengages the primary transfer roller
Yes
Pickup motor (M5) Tray 1 pickup roller
Tray 2 cassette pickup roller
Feed roller
No
Developing
disengagement motor
(M6)
Engages and disengages the developing unit No
Duplex reverse motor
(M7; duplex models
only)
Duplex reverse roller No
Duplex feed motor (M8;
duplex models only)
Duplex feed roller No
Tray 2 cassette lifter
motor (M9)
Lifter for the Tray 2 cassette No
Scanner motor (M10) Scanner mirror No
ENWW Engine-control system 13
Fans
The product uses three fans to maintain the correct internal temperature. The DC controller determines a
fan failure when a fan locks for a specified period after it starts driving.
Figure 1-5 Fans
Power supply fan
Fuser fan
Formatter fan
Table 1-4 Fans
Description Area cooled Type Speed
Power supply fan
(FM1)
Low-voltage power supply
Output bin
Delivery unit
Laser scanner unit
Intake Full/Half
Fuser (FM2) Duplex feed unit
ITB area
Intake Full
Formatter (FM3) Formatter area Intake Controlled by
the formatter
14 Chapter 1 Theory of operation ENWW
Fuser-control circuit
The fuser-control circuit monitors and controls the temperature in the fuser. The product uses on-demand
fusing. The fuser-control circuit consists of the following major components:
●Fuser main heater (H1): Heats the center of the fuser sleeve
●Fuser sub heater (H2): Heats the ends of the fuser sleeve
●Thermistors; detect the fuser temperature (contact type)
◦Sleeve thermistor (TH1): Detects the temperature at the center of the fuser sleeve
◦Main thermistor (TH2): Detects the temperature at the center of the fuser heater
◦Sub thermistor 1 (TH3): Detects the temperature at the end of the fuser heater nearest the front
of the product
◦Sub thermistor 2 (TH4): Detects the temperature at the end of the fuser heater nearest the rear
of the product
●Thermal fuse (FU1): Prevents abnormal temperature rise in the fuser heater (non-contact type)
Figure 1-6 Fuser-control circuit
H1
FUSER TEMPERATURE signal
Pressure roller
FUSER HEATER
CONTROL signal
TH4
TH2
FU1
TH3
Fuser sleeve
Fuser heater
control circuit
Fuser heater
safety circuit
Low-voltage power supply
DC controller
H2
TH1
Front of engine
ENWW Engine-control system 15
Fuser temperature control
The fuser temperature control maintains the fuser heater at its targeted temperature.
The fuser main heater and sub heater control the temperature of the fuser sleeve.
The DC controller monitors the main thermistor and the sleeve thermistor. The DC controller controls the
FUSER MAIN HEATER CONTROL (FSRD1) and the FUSER SUB-HEATER CONTROL (FSRD2) signals
according to the detected temperature. The fuser-heater control circuit controls the fuser heater
depending on the signal so that the heater remains at the targeted temperature.
Figure 1-7 Fuser-heater control circuit
Noise filter
DC controller
Fuser presence circuit
FU1
TH1
TH2
TH3 TH4
Fuser sleeve
Fuser heater
safety circuit
RLD1
RLD2
FSRD1
FSRD2
ZEROX
FUSEROPEN
FUHL
THERM1
THERM2
THERM4
THERM3
FU102
Improper fuser installation prevention circuit
AC input
H1
H2
RL102
RL103
Low-voltage power supply
Fuser heater
control circuit
Zerocross
circuit
Fuser
16 Chapter 1 Theory of operation ENWW
Fuser protective function
The protective function detects an abnormal temperature rise of the fuser unit and interrupts power
supply to the fuser heater.
The following three protective components prevent an abnormal temperature rise of the fuser heater:
●DC controller
◦The DC controller interrupts power supply to the fuser heater when it detects an abnormal
temperature of the fuser heater.
●Fuser-heater safety circuit
◦The fuser heater safety circuit interrupts power supply to the fuser heater when the detected
temperature of the main and sub thermistors is abnormal.
●Thermal fuse
◦The thermal fuse is broken to interrupt power supply to the fuser heater when the
thermoswitch detects an abnormal temperature of the fuser heater.
◦The current detection circuit detects the current value flowing in the fuser heater control
circuit. The DC controller deactivates the FUSER HEATER CONTROL signal and releases the
relay to interrupt power supply to the fuser heater when it detects a specified current value or
higher by the CURRENT DETECTION (FUR_CURRMS) signal.
ENWW Engine-control system 17
Fuser failure detection
The DC controller determines a fuser unit failure, deactivates the FUSER HEATER CONTROL signal,
releases the relay to interrupt power supply to the fuser heater, and then notifies the formatter of a
failure state when it encounters the following conditions:
●Abnormal temperature rise: The sleeve thermistor does not rise at a specified temperature within a
specified period after the fuser heater control starts.
●Abnormally low temperature: The thermistors are at a specified temperature or lower during a
print operation or other fuser heating cycle.
●Abnormally high temperature: The thermistors are at a specified temperature or higher, regardless
of the fuser control status.
●Drive circuit abnormality: The frequency in the zerocross circuit is out of a specified range when
the product is turned on or is in the standby period.
18 Chapter 1 Theory of operation ENWW
Low-voltage power supply
The low-voltage power supply (LVPS) converts AC input voltage to DC voltage.
Figure 1-8 Low-voltage power supply
FU102
FU101
Formatter
+3.3V generation
circuit
Power switch
Remote switch
control circuit
+3.3V
SWON/OFF
PWRON
+24V generation
circuit
+5V generation
circuit
+24V
Interlock switch
DC controller
ZEROX
REMOTEON
RLD1
RLD2
+3.3V
Protection
circuit
Fuser
Fuser heater
control circuit
Noise filter
Noise filter
Rectifying circuit
Zerocross
circuit
+24V
+5V
+24R
+5R
Low-voltage power supply
RL101
RL102
RL103
SW1
SW2
SW3
SW4
+5V
Interlock switch
The product uses three DC voltages: 24V, 5V, and 3.3V. The voltages are subdivided as follows:
+24V Supplied constantly
Stopped during Sleep mode
+24R Interrupted when the front or right door is opened
ENWW Engine-control system 19
+5V Supplied constantly
Stopped during Sleep mode
+5R Interrupted when the front or right door is opened
+3.3V Supplied constantly
20 Chapter 1 Theory of operation ENWW
Overcurrent/overvoltage protection
The low-voltage power supply has a protective circuit against overcurrent and overvoltage to prevent
failures in the power supply circuit. The low-voltage power supply automatically stops supplying the DC
voltage whenever excessive current flows or voltage abnormally increases.
If the dc voltage is not being supplied from the low-voltage power supply, the protective function may
be running. In this case, turn off the power switch and unplug the power cord. Do not turn the power
switch on until the root cause is found.
The LVPS has two fuses on the PCA. The LVPS 24V output is interrupted to the fuser and the high-voltage
power supply if the either of the interlock switches (SW3 and SW4) is in the off position (door open).
WARNING! The product power switch only interrupts dc voltage from the LVPS. The AC voltage is
present in the product when the power cord is plugged into a power receptacle and the power switch
is in the off position. You must unplug the product power cord before servicing the product.
WARNING! If you believe the overcurrent or overvoltage protection circuits have been activated, do
not plug in the product power cord or turn on the product power until the cause of the failure is found
and corrected.
In addition, fuses in the low-voltage power supply protect against overcurrent. If overcurrent flows into
the AC line, the fuses melt and cut off the power distribution.
ENWW Engine-control system 21
High-voltage power supply
The DC controller controls the high-voltage power supply to generate biases.
Figure 1-9 High-voltage power supply
Secondary transfer bias circuit
TRS2
TRI-1
Primary charging bias circuit
DEV high-voltage power supply
DEV-4
DEV-3
DEV-2
DEV-1
PRI-4
DC controller
TR2 high-voltage power supply
Primary transfer bias circuit
TR1 high-voltage power supply
TRI-2
TRI-3
TRI-4
PRI-3
PRI-2
PRI-1
FG
Developing bias circuit
The high-voltage power supply (HVPS) applies biases to the following components:
●Primary charging roller: The primary charging bias is applied to the surface of the photosensitive
drum to charge it uniformly negative as a preparation for the image formation.
●Developing roller: The developing bias is used to adhere toner to an electrostatic latent image
formed on the photosensitive drum.
22 Chapter 1 Theory of operation ENWW
●Primary transfer roller: The primary transfer bias is used to transfer the toner from each
photosensitive drum onto the ITB.
●Secondary transfer roller: The secondary transfer bias is used to transfer the toner image from the
ITB onto the paper. The reversed bias is applied to transfer residual toner on the secondary
transfer roller back to the ITB. The residual toner on the ITB is deposited in the toner collection unit.
ENWW Engine-control system 23
Laser scanner system
The laser scanner system forms latent images on the photosensitive drums according to the VIDEO
signals sent from the formatter.
The main components of the laser/scanner are the laser unit and the scanner motor unit. The DC
controller sends signals to the laser/scanner to control the functions of these components.
Figure 1-10 Laser/scanner system
DC controller
Formatter
Scanner mirror
Scanner motor unit
SCANNER MOTOR CONTROL signal
VIDEO signal
LASER CONTROL signal
BDI signal
Laser unit (Y/M)
Laser unit (C/Bk)
Connecting board
Photosensitive drum
24 Chapter 1 Theory of operation ENWW
Laser failure detection
The DC controller determines an optical unit failure and notifies the formatter, if the laser/scanner
encounters the following conditions:
●The scanner motor does not reach a specified rotation frequency within a specified period of the
scanner motor start up.
●The beam detect (BD) interval is out of a specified value during a print operation.
ENWW Engine-control system 25
Image-formation system
Electrophotographic process
The electrophotographic process forms an image on the paper. Following are the major components
used in the process:
●Print cartridges
●Intermediate transfer belt (ITB)
●Secondary transfer roller
●Fuser
●Laser scanner
The DC controller uses the laser scanner and HVPS to form the toner image on the photosensitive drum.
The image is transferred to the print media and then fused onto the paper.
Figure 1-11 Electrophotographic process block diagram
ITB Fuser
Secondary transfer
roller
Cartridge
Laser scanner
DC controller
DEV high-voltage
power supply
TR2 high-voltage
power supply
TR1 high-voltage
power supply
26 Chapter 1 Theory of operation ENWW
Figure 1-12 Electrophotographic process drive system
Developing roller
Developing roller
Developing roller
Developing roller
Fuser motor
ITB motor
Drum motor
Developing motor
M2
M3 M1
M4
ENWW Image-formation system 27
Image formation process
Each of the following processes functions independently and must be coordinated with the other
product processes. Image formation consists of the following processes:
Latent-image formation block Step 1: pre-exposure
Step 2: primary charging
Step 3: laser-beam exposure
Developing block Step 4: developing
Transfer block Step 5: primary transfer
Step 6: secondary transfer
Step 7: separation
Fusing block Step 8: fusing
ITB cleaning block Step 9: ITB cleaning
Drum cleaning block Step 10: Drum cleaning
Figure 1-13 Image formation process
: Step
: Block
: Direction of drum rotation
: Media path
ITB cleaning
9. ITB cleaning
Developing
4. Developing
5. Primary transfer
10. Drum cleaning Drum cleaning
Latent image formation
1. Pre-exposure
2. Primary charging
3. Laser beam exposure
Pickup
Registration
Fuser
8. Fuser
Transfer
7. Separation
6. Secondary transfer
Delivery
28 Chapter 1 Theory of operation ENWW
Latent-image formation block
During the latent-image formation stage, the laser scanner forms invisible images on the photosensitive
drums in the print cartridges.
Pre-exposure
Step 1: Light from the pre-exposure LED strikes the photosensitive drum surface. This eliminates the
residual electrical charges on the drum surface.
Figure 1-14 Pre-exposure
Photosensitive drum
LED
Primary charging
Step 2: DC and AC biases are applied to the primary charging roller, which transfers a uniform
negative potential to the photosensitive drum.
Figure 1-15 Primary charging
Primary charging roller
Primary charging bias
Photosensitive drum
ENWW Image-formation system 29
Laser beam exposure
Step 3: The laser beam scans the photosensitive drum to neutralize negative charges on parts of the
drum surface. An electrostatic latent image is formed on the drum where negative charges were
neutralized.
Figure 1-16 Laser beam exposure
Laser beam
30 Chapter 1 Theory of operation ENWW
Developing block
Step 4: In the print cartridge, toner acquires a negative charge from the friction that occurs when the
developing roller rotates against the developing blade. The developing bias is applied to the
developing roller to create a difference in the electric potential of the drum. When the negatively
charged toner comes in contact with the photosensitive drum, it adheres to the latent image because the
drum surface has a higher potential.
Figure 1-17 Developing
Developing bias
Photosensitive drum
Developing roller
Developing blade
ENWW Image-formation system 31
Transfer block
Primary transfer
Step 5: The toner on the photosensitive drum is transferred to the intermediate transfer belt (ITB). The
ITB is given a positive charge by the bias of the primary transfer roller. The negatively charged toner on
the drum surface is transferred onto the ITB. All four color planes are transferred onto the ITB in this
step.
Figure 1-18 Primary transfer
ITB
Primary transfer bias
Primary transfer roller
Photosensitive
drum
Secondary transfer
Step 6: The toner image on the ITB is transferred to the paper. The secondary transfer bias is applied
to the secondary transfer roller to charge the paper positive. As the paper passes between the
secondary transfer roller and the ITB, the complete toner image on the ITB is transferred onto the paper.
Figure 1-19 Secondary transfer
ITB
Secondary transfer bias
Secondary transfer roller
Paper
Secondary transfer
opposed roller
32 Chapter 1 Theory of operation ENWW
Separation
Step 7: The elasticity of the paper and the curvature of the secondary transfer opposed roller cause the
paper to separate from the ITB. The static charge eliminator reduces back side static charge of the
paper and controls excess discharge after the transfer process for stable media feed and image quality.
Figure 1-20 Separation
ITB
Secondary transfer roller
Paper
Secondary transfer
opposed roller
Static charge eliminator
Fusing block
Step 8: The product uses an on-demand fuser. The toner image is permanently affixed to the printing
paper by heat and pressure.
Figure 1-21 Fusing
Paper
Pressure roller
Fuser sleeve
Fuser heater
Toner
ENWW Image-formation system 33
ITB cleaning block
Step 9: The cleaning blade scrapes the residual toner off the surface of the ITB. The residual toner feed
screw deposits residual toner in the toner collection unit.
Figure 1-22 ITB cleaning
ITB
Cleaning blade
Residual toner feed screw
Drum cleaning block
Step 10: The cleaning blade scrapes the residual toner off the surface of the photosensitive drum, and
toner is deposited in the waste section inside the print cartridge.
Figure 1-23 Drum cleaning
Cleaning blade
Photosensitive
drum
Toner waste
34 Chapter 1 Theory of operation ENWW
Print cartridges
The product has four print cartridges, one for each color: yellow, magenta, cyan, and black. Each of
them has the same structure. The cartridges are filled with toner and consist of the following
components:
●Photosensitive drum
●Developing unit
●Primary charging roller
The DC controller rotates the motors to drive the photosensitive drum, developing unit, and primary
charging roller.
Figure 1-24 Print cartridge block diagram
M6
M2
M3
DC controller
Developing unit
Memory tag
Developing
disengagement
motor
PS11:
Developing disengagement
sensor
Drum motor
Developing motor
Photosensitive drum
Primary charging roller
PS13:
YMC drum home
position sensor
ENWW Image-formation system 35
Memory tag
The memory tag is a non-volatile memory chip in the cartridge that stores information about usage for
the cartridge. The product reads and writes the data in the memory tag. The DC controller determines a
memory tag error and notifies the formatter when it fails to either read from or write to the memory tag.
Cartridge presence detection
The DC controller detects the presence of the cartridges by monitoring the cartridge e-label and ground
circuit. When the DC controller determines a cartridge absence, it notifies the formatter.
Toner level detection
The DC controller detects the remaining toner level in a cartridge by the optical detection method. The
DC controller notifies the formatter of the remaining toner level.
Cartridge life detection
The DC controller detects the cartridge life by monitoring the total operational wear limit or remaining
toner level of the cartridge. The DC controller determines a cartridge end of life and notifies the
formatter when the operational wear limit of the cartridge reaches a specified amount or the cartridge
runs out of toner.
Developing unit engagement and disengagement control
The developing unit engagement and disengagement control engages the developing unit with the
photosensitive drum or disengages the developing unit from the drum depending on the print mode: full-
color mode or black-only mode. The developing unit is engaged only when required, preventing a
deterioration of the drums and maximizing their life.
The developing disengagement motor rotates the developing disengagement cam. As the cam rotates,
the developing unit engages with or separates from the photosensitive drum.
When the product is turned on and when each print job is completed, all four of the developing units
disengage from the photosensitive drums. When the print mode is in full-color mode, all of the
developing units engage with the drums. When the print mode is in black-only mode, only black
developing unit engages with the drum.
36 Chapter 1 Theory of operation ENWW
The DC controller determines a developing disengagement motor abnormality and notifies the formatter
when it does not detect a specified signal from the developing disengagement sensor during the
developing roller engagement and disengagement operation.
Figure 1-25 Developing unit engagement and disengagement control
M6
DC controller
Developing disengagement motor
Developing unit
Developing disengagement cam
Photosensitive drum
PS11:
Developing
disengagement
sensor
Developing unit is engaged
Developing unit is disengaged
ENWW Image-formation system 37
ITB unit
The ITB unit receives the toner image from the photosensitive drums and transfers the complete toner
image to the print media. The ITB unit consists of the following components:
●ITB
●ITB drive roller
●Primary transfer rollers
●ITB cleaner
The ITB motor drives the ITB drive roller which rotates the ITB. The rotation of the ITB causes the primary
transfer rollers to rotate. The ITB cleaner cleans the ITB surface.
Figure 1-26 ITB unit block diagram
ITB
M1 ITB motor
ITB cleaner
Primary transfer roller
ITB drive roller
DC controller
38 Chapter 1 Theory of operation ENWW
Primary transfer roller engagement and disengagement control
Figure 1-27 Primary transfer roller engagement and disengagement control
ITB
SL5
SW5
M4
DC controller
Fuser motor
Primary transfer
disengagement solenoid
Primary transfer
disengagement switch
Primary transfer
disengagement cam
Bk slide plate
YMC slide plate
<Only black is engaged>
<All colors are engaged>
<All colors are disengaged>
Primary transfer roller
Photosensitive drum
ENWW Image-formation system 39
The primary transfer roller engagement and disengagement control engages the ITB with the
photosensitive drum, or disengages the ITB from the drum, depending on the requirements of the print
job.
●All rollers disengaged: The ITB disengages from all four photosensitive drums. This is the state
during a standby period, and also is the home position for the primary transfer rollers.
●All rollers engaged: The ITB engages with all the four photosensitive drums. This is the state for
full-color jobs.
●Only black roller engaged: The ITB engages with only the black photosensitive drum. This is
the state for the black-only print jobs.
The operational sequence of the primary transfer roller engagement and disengagement control is as
follows:
1. The fuser motor drives the primary transfer disengagement solenoid to rotate the primary transfer
disengagement cam.
2. As the cam rotates, the YMC slide plate or the Bk slide plate moves to right or left. This causes the
primary transfer roller to move up or down.
3. The ITB engages with or disengages from the photosensitive drum depending on the movement of
the primary transfer rollers.
The DC controller determines that an abnormal primary transfer roller disengagement error has occured
and notifies the formatter. This error happens when the DC controller does not detect a specified signal
from the primary transfer disengagement switch, even though the primary transfer disengagement
solenoid is driven.
ITB unit presence detection
The DC controller detects the ITB unit presence by monitoring the primary transfer disengagement
switch. The DC controller drives the primary transfer disengagement solenoid for specified times during
the initial rotation period of the following:
●The product is turned on
●The product exits Sleep mode
●The door is closed
The DC controller determines an ITB unit absence and notifies the formatter when it does not detect a
specified signal from the primary transfer disengagement switch.
ITB cleaning mechanism
The cleaning blade in the ITB cleaner scrapes the residual toner off the ITB surface. The ITB motor drives
the residual toner feed screw and the screw deposits the residual toner in the toner collection unit.
The DC controller detects whether the toner collection unit is full by monitoring the ITB residual toner full
sensor. When the DC controller determines the toner collection unit is full, it notifies the formatter. The
40 Chapter 1 Theory of operation ENWW
DC controller also detects the presence of the toner collection unit by monitoring the toner collection unit
switch.
Figure 1-28 ITB cleaning mechanism
SW6 ITB
M1
DC controller
Toner collection unit switch
ITB residual toner full sensor Cleaning blade
ITB cleaner
ITB motor
Residual toner feed screw
Toner collection unit
Calibration
The product calibrates itself to print a high-quality image. The calibration corrects a color-misregistration
and color-density variation caused by environment changes or variation inherent in the product. The
product performs the following calibrations:
●Color-misregistration control
●Environment change control
●Image stabilization control
ENWW Image-formation system 41
Color-misregistration control
The color-misregistration control corrects the misaligned color planes caused by the variation inherent in
the laser scanner units or cartridges. The color-misregistration control corrects the following:
●Horizontal scanning start position
●Horizontal scanning magnification
●Vertical scanning start position
The DC controller forms a pattern of toner on the surface of the ITB, and measures a misaligned length
with the registration density sensor and the registration density belt-perimeter sensor. Accordingly, the
formatter calibrates the color-misregistration.
Figure 1-29 Color-misregistration control
ITB
Pattern of toner
Regisration density sensor
Registration density
belt-perimeter sensor
The DC controller commands the formatter to perform the color-misregistration control whenever one of
the following occurs:
●The product is turned on or the door is closed, after replacing any one of the cartridges
●The product is turned on or the door is closed, after replacing the ITB unit or the laser scanner unit
●A specified number of pages have been printed
●Continuous printing for a specified period of time
●Cold starting of the fuser when the product is turned on
If data from the registration density or registration density belt-perimeter sensor is out of a specified
range during the cartridge-presence detection or when starting the color-misregistration control, the DC
controller determines an abnormal sensor and notifies the formatter.
42 Chapter 1 Theory of operation ENWW
Environment change control
The environment change control calibrates each high-voltage bias to obtain an appropriate image
according to the environment changes. The DC controller determines the environment, where the
product is installed, based on the surrounding temperature and humidity data from the environment
sensor. It adjusts the high-voltage biases to accommodate environmental changes.
The DC controller determines an environment sensor abnormality and notifies the formatter when it
detects out of specified range data from the environment sensor.
Image stabilization control
The image stabilization control reduces the fluctuations in image density caused by environmental
changes or deterioration of the photosensitive drums or toner. The two kinds of image stabilization
controls are image density control (DMAX) and image halftone control (DHALF).
Image density control (DMAX)
The image density control calibrates each high-voltage bias to stabilize the image density variation
caused by the deterioration of the photosensitive drum or toner. The DC controller commands the
formatter to control the image density under the following conditions:
●The detected temperature of the fuser is a specified degree or lower when the product is turned on
●The product is turned on, or the door is closed, and also whenever a specified number of pages
have been printed after replacing any one of the cartridges
●The product is turned, on or the door is closed, after replacing the ITB unit or the laser scanner unit
●A specified number of pages have been printed
●After a specified period of time from the previous image density control
●The environment is changed for a specified condition after the previous image density control
Image halftone control (DHALF)
The image halftone control is performed by the formatter to calibrate the halftone. The DC controller
measures the halftone pattern according to a command from the formatter. Accordingly, the formatter
calibrates the halftone. The DC controller controls the image halftone under the following conditions:
●The image density control is completed
●The formatter sends a command
ENWW Image-formation system 43
Pickup, feed, and delivery system
The pickup/feed/delivery system consists of several types of feed rollers and sensors. The duplex model
has a mechanism that reverses and refeeds the print media to print two sides automatically.
Figure 1-30 Pickup, feed, and delivery system
Fuser sleeve
Pressure roller
Duplex feed roller
(duplex model only)
T2 roller
MP tray pickup roller
MP tray separation pad
Cassette separation roller
Cassette pickup roller
Simplex paper path
Duplex paper path (duplex model)
Duplex reverse roller
(for duplex model)
Duplex flapper
(for duplex model)
The pickup/feed/delivery system can be divided into the following three blocks:
●Pickup-and-feed block: From each input source to the fuser inlet
●Fuser-and-delivery block: From the fuser to the output bin
●Duplex block: From the duplex reverse unit to the duplex re-pickup unit (duplex models only)
44 Chapter 1 Theory of operation ENWW
Figure 1-31 Pickup, feed, and delivery system blocks
Duplex block
Pickup-and-feed block
Fuser-and-delivery block
ENWW Pickup, feed, and delivery system 45
Photo sensors
Figure 1-32 Photo sensors (paper path)
PS3
PS2
PS1
PS4
PS10
PS6
PS7
PS8
PS5
MS
Table 1-5 Photo sensors and switches (product)
Item Description Item Description
PS1 Tray 2 cassette paper-presence sensor PS6 Fuser delivery sensor
PS2 Tray 1 (MP tray) paper-presence sensor PS7 Loop sensor 1
PS3 Last-paper sensor PS8 Loop sensor 1
PS4 Tray 2 cassette paper-stack surface sensor PS10 Output bin media-full sensor
PS5 Top-of-Page (TOP) sensor
46 Chapter 1 Theory of operation ENWW
Motors and solenoids
Figure 1-33 Motors and solenoids (paper path)
M4
SL3
M1
M9 M5
SL2
SL1
M7
M8
For duplex model only
Table 1-6 Motors and solenoids (paper path)
Item Description Item Description
M1 ITB motor M9 Tray 2 cassette lifter motor
M4 Fuser motor SL1 Tray 2 cassette pickup solenoid
M5 Pickup motor SL2 Tray 1 (MP tray) pickup solenoid
M7 Duplex reverse motor (duplex models only) SL3 Duplex reverse solenoid 1 (duplex models only)
M8 Duplex feed motor (duplex models only)
Pickup and feed block
The pickup-and-feed block picks one sheet of paper from the Tray 2 cassette or the MP tray and feeds it
into the fuser.
ENWW Pickup, feed, and delivery system 47
Tray 2 cassette pickup
The operational sequence of the Tray 2 cassette pickup is as follows:
1. The product is turned on or the Tray 2 cassette is inserted.
2. The lift-up operation and the lifting plate spring move up the lifting plate to the position where the
paper can be picked up.
3. The DC controller rotates the pickup motor when it receives a print command from the formatter.
4. The Tray 2 cassette (CST) feed roller rotates.
5. The Tray 2 cassette (CST) pickup solenoid is driven at a specified timing.
6. The Tray 2 cassette (CST) pickup roller rotates and picks up the paper.
7. The Tray 2 cassette (CST) separation roller removes any multiple-fed sheets.
8. One sheet of paper is fed into the product.
NOTE: The lift-up operation pushes up the lifting plate to keep the stack surface of paper at the
pickup position.
Figure 1-34 Tray 2 cassette pickup operation
SL1
M5
DC controller
Pickup motor
CST pickup solenoid
CST pickup roller
CST feed roller
CST separation roller
Lifter
Lifting plate spring
48 Chapter 1 Theory of operation ENWW
Tray 2 cassette multiple-feed prevention
The product uses a separation roller method to prevent multiple sheets of print media from entering the
paper path. The Tray 2 cassette separation roller does not have its own driving force. Therefore the
Tray 2 cassette separation roller follows the rotation of the Tray 2 cassette pickup roller.
During normal feed, when the product picks up one piece of paper, the Tray 2 cassette separation
roller is driven by the Tray 2 cassette pickup roller through one sheet of paper. Thus the separation
roller rotates in the paper feed direction.
During multiple-feed, when the product picks up more than one piece of paper, the low friction force
between the sheets weakens the driving force from the Tray 2 cassette pickup roller. In addition, some
braking force is always applied to the Tray 2 cassette separation roller, so the weak rotational force of
the pickup roller is not enough to rotate the separation roller. Therefore, the separation roller holds
back any multiple-fed sheets, and one sheet of paper is fed into the product.
Figure 1-35 Tray 2 cassette multiple-feed prevention
CST Pickup roller
Print media
Lifting plate
<Normal-feed> <Multiple-feed>
The separation roller does not rotate
CST separation roller
ENWW Pickup, feed, and delivery system 49
Tray 2 cassette media-size detection and Tray 2 cassette-presence detection
The DC controller detects the size of paper loaded in the Tray 2 cassette by using the Tray 2 cassette-
media-end switch and Tary 2 cassette media width switch.
The DC controller also detects the presence of the cassette by using the Tray 2 cassette media end
switch. The DC controller notifies the formatter if the Tray 2 cassette is absent.
Table 1-7 Tray 2 cassette media-size detection and Tray 2 cassette-presence detection (product
base)
Paper size Cassette media width sensor Cassette media end switch
Top switch Center switch Bottom switch Top switch
1
Center switch Bottom switch
A4 On On On See footnote Off Off
Letter On On Off Off Off
B5 On Off Off Off Off
Executive Off Off Off Off Off
A5-R Off On On Off Off
B5-R Off Off On Off Off
Letter-R On Off On Off Off
A4-R On Off On Off On
A3 On On On On On
11 X 17 On On Off On On
B4 On Off Off On On
Legal On Off On On On
1
The top Tray 2 cassette-media-end switch detects the presence of the Tray 2 cassette. It turns off when the Tray 2 cassette is
present and turns on when the Tray 2 cassette is absent.
50 Chapter 1 Theory of operation ENWW
Tray 2 cassette lift-up operation
The cassette lift-up operation keeps the surface of the paper stack surface at the correct pickup position
whenever the following conditions occur:
●Product power is turned on
●Tray 2 cassette is installed
The list below describes the sequence of the Tray 2 cassette lift-up operation.
●The Tray 2 cassette lifter motor rotates to move the lifter rack toward the Tray 2 cassette-media-
stack surface sensor.
●As the lifter rack moves, the lifter moves up.
●The Tray 2 cassette lifter motor stops when the Tray 2 cassette-media-stack surface sensor detects
the lifter rack.
ENWW Pickup, feed, and delivery system 51
The DC controller determines a Tray 2 cassette lifter motor failure and notifies the formatter if the Tray 2
cassette-media-stack surface sensor does not detect the lifter rack within a specified period after the
Tray 2 cassette lifter motor starts rotating.
Figure 1-36 Tary 2 cassette lift-up operation
M9
1
2
3
DC controller
Cassette lifter motor
Lifter
Lifting plate
Lifter rack
Lifter drive ass’y
Cassette
PS4:
Cassette media stack surface sensor
52 Chapter 1 Theory of operation ENWW
Cassette media-presence detection
The Tray 2 cassette-media-out sensor detects the presence of paper in the Tray 2 cassette.
The DC controller notifies the formatter when the Tray 2 cassette-media-out sensor detects the media is
absent.
Figure 1-37 Tray 2 cassette media-presence detection
PS1
Cassette media out sensor
Cassette media out sensor flag
DC controller
Tray 1 (MP tray) paper pickup
The operational sequence of the MP tray pickup is as follows:
1. The DC controller rotates the pickup motor when it receives a print command from the formatter.
2. As the MP tray pickup solenoid is driven, the MP tray pickup roller rotates and the lifting plate
moves up.
3. The MP tray pickup roller picks up the paper.
4. The MP tray separation pad removes any multiple-fed sheets and one sheet of paper is fed into the
product.
ENWW Pickup, feed, and delivery system 53
The MP tray media presence sensor detects the presence of print media on the MP tray.
Figure 1-38 Tray 1 (MP tray) paper pickup
MP tray pickup roller
MP tray separation pad
SL2
M5
PS2:
MP tray media presence sensor
Pickup motor
MP tray pickup solenoid
Lifting plate
DC controller
Tray 1 (MP tray) last-paper detection
The product detects whether the print media on the MP tray is the last sheet during continuous printing
to prevent toner contamination on the photosensitive drums and the ITB.
The product attempts to form the next image before the DC controller detects a media absence because
the paper path between the MP tray media-presence sensor and the registration roller is short. To
prevent the photosensitive drums and the ITB from being contaminated with toner, the last-paper sensor
detects the last-paper. The MP tray last-paper detection roller rotates when the last-paper is picked up.
54 Chapter 1 Theory of operation ENWW
The DC controller notifies the formatter of a media absence when it detects the last-paper by the last-
paper sensor.
Figure 1-39 Tray 1 (MP tray) last-paper detection
A
DC controller
PS3:
Last-paper sensor
Last-paper
MP tray last-paper detection roller
Cross sectional view from A direction
Feed direction
Paper feed
After the paper pickup operation, the paper picked up from either the Tray 2 cassette or MP tray is then
fed to the fixing-and-delivery block.
1. The registration shutter corrects the skew-feeding of the paper that is picked up from the Tray 2
cassette or MP tray.
2. When the TOP sensor detects the leading edge of paper, the DC controller controls the rotational
speed of the pickup motor to align with the leading edge of toner image on the ITB.
3. The toner image on the ITB is transferred onto the paper, and the paper is fed to the fusing-and-
delivery block.
ENWW Pickup, feed, and delivery system 55
The DC controller notifies the formatter of a paper size mismatch error when the paper length detected
by the TOP sensor does not match the paper size specified by the formatter.
Figure 1-40 Paper feed
TOP sensor
M1 M5
Registration shutter
Registration roller
Pickup motor
ITB motor
DC controller
PS5
56 Chapter 1 Theory of operation ENWW
Skew-feed prevention
The printer corrects the skew feed without decreasing the throughput.
1. The leading edge of paper strikes the registration shutter and aligns.
2. As the feed rollers keep pushing the paper, the paper gets warped against the registration shutter.
3. The stiffness of paper pushes up the registration shutter and the realigned paper passes through
straightened.
Figure 1-41 Skew-feed prevention
Paper
Paper
Registration shutter
Registration shutter
ENWW Pickup, feed, and delivery system 57
Media detection
The product automatically selects an optimal print mode for a print-media by monitoring the media
sensors on the paper path.
Media detection sensor types
●Reflected light type (detects the glossiness of paper)
●Transmitted light type (detects the thickness of paper)
The DC controller detects the type of print-media by the reflected light and the transmitted light, and
switches the print modes accordingly. The DC controller identifies the following paper type:
●Plain paper
●Light paper
●Heavy paper
●Glossy paper
●Glossy film
●Overhead transparency (OHT)
The DC controller determines a media mismatch error and notifies the formatter under the following
conditions:
●Simplex printing
◦The specified print mode is OHT, but the media sensor detects media other than an overhead
transparency.
◦The specified print mode is something other than OHT, but the media sensor detects an
overhead transparency.
●Duplex printing
◦The specified print mode is for duplex-printable-print mode, but the media sensor detects an
overhead transparency. For more information about duplex-printable mode, see Duplex block
(duplex models only) on page 63.
The DC controller flashes the media sensor during the initial rotation period under the following
conditions:
●Product power is turned on
●The door is closed
The DC controller determines a media sensor abnormality and notifies the formatter when the light
intensity is out of a specified range.
58 Chapter 1 Theory of operation ENWW
Feed-speed control
The product adjusts the feed speed to obtain the best print quality depending on the type of print
media. The product prints at the speed corresponding to the print mode specified by the formatter.
Auto Sense mode Print mode Print
speed
Media
sensor
detection
Normal mode Normal 1/1 Yes
Light mode Light media 1 1/1 Yes
Heavy Mode Heavy media 1 2/3 Yes
Cardstock Mode Heavy media 3 1/3 No
Transparency Mode OHT 1/3 Yes
Transparency2 Mode OHT + higher fuser temp 1/3 Yes
Envelope Mode Envelope 2/3 No
Label Mode Label 1/3 No
Tough Mode Glossy film 1/3 Yes
Extra Heavy Mode Heavy media 2 1/3 Yes
Heavy Glossy Mode Glossy media 1 2/3 Yes
X-hvyglossymode Glossy media 2 1/3 Yes
Rough Mode Rough 2/3 No
Card Glossy Mode Glossy media 3 1/3 Yes
4mm trns Mode OHT + lower fuser temp 1/3 Yes
Light Rough Mode Light media 1 + fuser temp adjustments 1/1 Yes
Fusing and delivery block
The fusing-and-delivery block fuses the toner image onto the print media and delivers the printed page
to the output bin.
Loop control
The product controls the loop (slackness) of print media to prevent the defects of print quality and media
feed.
●If the fuser sleeve rotates slower than the ITB, the paper loop increases and an image defect or
paper crease occurs.
●If the fuser sleeve rotates faster than the ITB, the paper loop decreases and an image is stretched
because the toner image is not transferred to the paper correctly
ENWW Pickup, feed, and delivery system 59
Two loop sensors located between the fuser sleeve and the ITB detect the paper loop. Accordingly the
DC controller controls the rotational speed of the fuser motor to keep the loop amount properly.
●Loop sensor 1: Detects the paper loop for heavy media
●Loop sensor 2: Detects the paper loop for plain media other than heavy media
Figure 1-42 Loop control
Pressure roller
DC controller
M5
Loop sensor1
Loop sensor2
Sensor flag for heavy paper
Sensor flag for other than heavy paper
Fuser motor
Speed of fuser motor
OFF
ON
ON
OFF
OFF
ON
Speed down
Heavy media: Speed up
Other media: Speed down
Speed up
A
B
C
Pressure roller
ITB
<A> <B> <C>
PS7
PS8
Small-loop Large-loop
(heavy media)
Large-loop
(other than heavy media)
Loop sensor1 Loop sensor2 Illus.
Fuser sleeve
Fuser sleeve
60 Chapter 1 Theory of operation ENWW
Pressure roller pressurization and depressurization control
The product releases the pressure roller from the fuser sleeve, except during printing, to prevent
deforming the fuser sleeve and the pressure roller and to facilitate the jam-clearing procedure.
1. The DC controller reverses the fuser motor to rotate the fuser pressure release cam.
2. The pressure roller is pressurized or depressurized depending on the position of the cam.
The DC controller determines a fuser pressure-release mechanism abnormality and notifies the formatter
when it does not sense the fuser pressure-release sensor for a specified period from when it reverses the
fuser motor.
Figure 1-43 Pressure roller pressurization and depressurization control
M4
DC controller
Fuser motor
PS9:
Fuser pressure release sensor
Fuser sleeve
Pressure roller
Fuser pressure release cam
<Pressurized> <Depressurized>
ENWW Pickup, feed, and delivery system 61
Output bin full detection
The output bin media-full sensor detects whether the output bin is full of printed pages. The DC
controller determines the output bin is full and notifies the formatter when it senses the output bin media-
full sensor is on for a specified period during standby or printing.
Figure 1-44 Output bin full detection
Output bin media full sensor flag
Output bin media full sensor
DC controller
PS10
62 Chapter 1 Theory of operation ENWW
Duplex block (duplex models only)
The duplex block reverses and feeds the paper.
Figure 1-45 Duplex block
Duplex block
Simplex paper path
Duplex paper path (duplex model)
Only for the duplex model
Duplex reverse and duplex feed control
The duplex reverse control reverses the paper after the first side is printed. The duplex feed control
feeds the paper to the duplex block to print the second side of the page.
The operational sequence of the duplex reverse and duplex feed control is as follows:
1. The DC controller rotates the duplex reverse motor and drives the duplex reverse solenoid at a
specified timing after the first side of page is printed.
2. The duplex flapper moves and the paper is fed by the duplex reverse roller.
3. The duplex reverse motor is reversed.
4. The duplex reverse roller is reversed accordingly the paper is switched back.
ENWW Pickup, feed, and delivery system 63
5. The duplex feed motor rotates.
6. The duplex feed roller feeds the paper.
Figure 1-46 Duplex operation
DC controller
Duplex reverse solenoid
Duplex feed roller
Duplex ass’y
Simplex paper path
Duplex paper path (duplex model)
Duplex reverse roller
Duplex flapper
Only for the duplex model
SL3
M7
M8 Duplex feed motor
Duplex reverse motor
Duplex operation
The product prints two sides of paper with the following operation depending on the paper size.
●One-sheet operation: Feeds one sheet of two-sided page in a duplex print operation
●Two-sheet operation: Feeds two sheets of two-sided page in a duplex print operation
The duplex print operation is specified by the formatter.
The duplex print is performed only with the duplex printable paper size and specified print mode. See
Table 1-8 Paper sizes, duplex operation on page 65 and Table 1-9 Print modes, duplex operation
on page 65.
64 Chapter 1 Theory of operation ENWW
Table 1-8 Paper sizes, duplex operation
Paper size Duplexing media feed mode
A4-R One-sheet operation
A3
Letter-R
B4
B5-R
Ledger
Legal
A4 One-sheet operation
Two-sheet operation
B5
Letter
A5-R
Executive
Table 1-9 Print modes, duplex operation
Print mode Duplex print
1
Print mode Duplex print
1
AUTO Yes X-hvyglossy Yes
Normal Yes Card glossy No
Light Yes Rough Yes
Light rough Yes Transparency No
Heavy Yes 4mm transparency No
Extra heavy No Tough Yes
Cardstock No Label No
heavy glossy Yes Envelop No
1
This table shows whether the automatic duplex operation is available for each print mode, but it does not mean that the print-
quality of the automatic duplex print operation will be acceptable.
ENWW Pickup, feed, and delivery system 65
Jam detection
The product uses the following sensors to detect the presence of print-media and to check whether the
print-media is being fed correctly or has jammed:
●TOP sensor (PS5)
●Fuser delivery sensor (PS6)
●Loop sensor 1 (PS7)
●Loop sensor 2 (PS8)
●Output bin media full sensor (PS10)
Figure 1-47 Sensors for jam detection
PS6
PS7
PS8
PS5
Simplex media path
Duplex media path (duplex model)
PS10
The product detects the following jams:
Pickup delay jam Tray 1 (MP tray): The TOP sensor does not detect the leading edge of paper within a
specified period, including a retry, after the MP tray pickup solenoid is turned on.
Tray 2 cassette: The TOP sensor does not detect the leading edge of paper within a
specified period, including a retry, after the Tray 2 cassette pickup solenoid is turned on.
Paper feeder: The TOP sensor does not detect the leading edge of paper within a specified
period after the paper-feeder (PF) feed sensor detects the leading edge.
Pickup stationary jam The TOP sensor does not detect the trailing edge of paper within a specified period after the
leading edge of paper reaches the secondary transfer roller unit.
Fuser delivery delay jam The fuser delivery sensor does not detect the leading edge of paper within a specified period
after the leading edge of paper reaches the secondary transfer roller unit.
66 Chapter 1 Theory of operation ENWW
Fuser delivery stationary jam The fuser delivery sensor does not detect the trailing edge of paper within a specified period
after the TOP sensor detects the trailing edge.
The output bin media full sensor does not detect the leading edge of paper within a specified
period after the fuser delivery sensor detects the leading edge.
Wrapping jam The fuser delivery sensor detects a paper absence yet it does not detect the trailing edge of
paper after it detects the leading edge.
Residual paper jam One of the following sensors detects a presence of paper when the printer is turned on or
when the door is closed.
●TOP sensor
●Fuser delivery sensor
●Loop sensor 1
●Loop sensor 2
NOTE: The product automatically clears all paper from the paper path if the TOP sensor
detects residual paper when the product is turned on or a door is closed.
Door open jam The door open is detected during a paper feed operation.
Duplex re-pickup jam (duplex
model only)
The TOP sensor does not detect the leading edge of paper within a specified period after the
paper is reversed during a duplex print operation.
ENWW Pickup, feed, and delivery system 67
Paper feeder
This product supports a 500-sheet tray (Tray 3). The operational sequence of the paper feeder is
controlled by the paper feeder controller PCA.
Figure 1-48 Paper-feeder paper path
PF pickup roller
PF feed roller
PF separation roller
Figure 1-49 Paper-feeder block diagram
+24V
DC controller
+3.3V
Paper feeder
Paper feeder
controller
Motor
Solenoid
Photointerrupter
Switch
68 Chapter 1 Theory of operation ENWW
Paper-feeder motors
The paper feeder has two motors for paper feed and cassette lift-up operation.
Figure 1-50 Paper-feeder motors
PF lifter motor (M2)
PF pickup motor (M1)
Table 1-10 Paper-feeder motors
Motor Driving part Failure detection
PF pickup motor (M1) PF pickup roller
PF separation roller
PF feed roller
No
PF lifter motor (M2) Lifter for the PF cassette No
ENWW Paper feeder 69
Paper-feeder paper pickup and feed
The pickup-and-feed operation picks up one sheet of print media in the paper-feeder cassette and feeds
it to the product.
Figure 1-51 Paper-feeder electrical components
M1
M2
SL1
SR1
SR2
SR3
SW1
SW2SW3
Table 1-11 Paper-feeder electrical components
Component type Abbreviation Description
Motor M1 PF pickup motor
M2 PF lifter motor
Solenoid SL01 PF pickup solenoid
Photointerruptor (sensor) SR1 PF paper-feed sensor
SR2 PF paper-stack surface sensor
SR3 PF cassette paper-presence sensor
Switch SW1 PF door-open switch
SW2 PF cassette paper end-plate position switch
SW3 PF cassette paper-width switch
Cassette media-size detection and cassette-presence detection
The paper feeder detects the size of the paper loaded in the paper feeder cassette by monitoring the
paper feeder cassette media end switch and the paper feeder cassette media width switch. It also
detects the presence of cassette by monitoring the switches. The paper feeder controller notifies the
formatter through the DC controller when it determines a cassette is absent.
70 Chapter 1 Theory of operation ENWW
Table 1-12 Cassette media-size detection and cassette-presence detection (Tray 3)
Paper size Paper feeder
Cassette media-width sensor
Paper feeder
Cassette media-end switch
Top switch Center switch Bottom switch Top switch Center switch Bottom switch
Executive Off On On On On On
Letter Off Off On On On On
A5 On On Off On On On
B5 Off On Off On On On
A4OffOffOffOnOnOn
Ledger Off Off On Off Off On
LegalOnOnOffOffOffOn
B4 Off On Off Off Off On
A3 Off Off Off Off Off On
A4-R NOTE: The product cannot detect the paper size of A4-R and Letter-R. If A4-R or Letter-R sized paper is
loaded to the cassette, A5 size is notified to the formatter.
Letter-R
UniversalOnOnOffOffOnOn
Cassette absent Off Off Off Off Off Off
Paper-feeder cassette lift operation
The cassette lift-up operation keeps the surface of the paper stack at the pickup position whenever the
following occurs:
●Product power is turned on
●Cassette is installed
●Stack surface in the cassette lowers
The operational sequence of the cassette lift-up is as follows:
1. The PF lifter motor rotates to raise the lifter.
2. When the PF paper-stack surface sensor detects the surface of the paper stack, the PF lifter motor
stops.
3. The lifter motor rotates again when the PF paper-stack surface detects that the paper surface is
lowered during a print operation.
ENWW Paper feeder 71
The paper feeder controller PCA determines a PF lifter motor failure and notifies the formatter through
the DC controller when the PF paper-stack surface sensor does not detect the stack surface within a
specified period after the PF lifter motor starts rotating.
Figure 1-52 Paper-feeder cassette lift operation
M2
SR2
SR3
Lifter
Lifting plate
PF lifter motor PF media stack surface flag
PF cassette media presence sensor flag
PF media stack surface sensor
PF cassette media presence sensor
Paper-feeder jam detection
The paper feeder uses the PF paper-feed sensor (SR1) to detect the presence of print-media and to
check whether print-media is being fed correctly or has jammed.
Figure 1-53 Paper-feeder jam detection
SR1
Paper feeder 1
The paper feeder detects the following jams:
PF pickup delay jam The PF paper-feed sensor does not detect the leading edge of paper within a specified period,
including a retry, after the PF pickup solenoid is turned on.
PF residual paper jam The PF paper-feed sensor detects a presence of paper when the printer is turned on, when the
door is closed or when the automatic delivery is performed.
PF door open jam A door open is detected during paper-feed operation.
72 Chapter 1 Theory of operation ENWW
Optional 3X500-sheet paper deck
The 3x500-sheet paper deck is installed at bottom of the product. It picks up the paper and feeds it to
the printer. The paper deck controller controls the operational sequence of the paper deck.
Figure 1-54 3X500-sheet paper deck
Paper deck cassette 1
Paper deck cassette 2
Paper deck cassette 3
Paper feeder
Paper deck cassette pickup roller
Paper deck cassette feed roller
Paper deck cassette separation roller
The signal flow of the paper deck controller is shown below.
ENWW Optional 3X500-sheet paper deck 73
Figure 1-55 3X500-sheet paper deck block diagram
DC controller Paper deck
controller 1
Motor
Solenoid
Photointerrupter
Switch
Paper deck cassette 1
+24V
+3.3V
Paper deck
controller 2
Paper deck
controller 3
Paper deck cassette 2
Paper deck cassette 3
Motor
Solenoid
Photointerrupter
Motor
Solenoid
Photointerrupter
Table 1-13 3X500-sheet paper deck
Component Description
Motor M1 Paper deck cassette 1 pickup motor
M2 Paper deck cassette 1 lifter motor
M81 Paper deck cassette 2 pickup motor
M82 Paper deck cassette 2 lifter motor
M91 Paper deck cassette 3 pickup motor
M92 Paper deck cassette 3 lifter motor
74 Chapter 1 Theory of operation ENWW
Table 1-13 3X500-sheet paper deck (continued)
Component Description
Solenoid SL1 Paper deck cassette 1 pickup solenoid
SL82 Paper deck cassette 2 pickup solenoid
SL92 Paper deck cassette 3 pickup solenoid
Photointerrupter SR1 Paper deck cassette 1 media feed sensor
SR2 Paper deck cassette 1 stack surface sensor
SR3 Paper deck cassette 1 cassette media out sensor
SR81 Paper deck cassette 2 media feed sensor
SR82 Paper deck cassette 2 stack surface sensor
SR83 Paper deck cassette 2 cassette media out sensor
SR91 Paper deck cassette 3 media feed sensor
SR92 Paper deck cassette 3 stack surface sensor
SR93 Paper deck cassette 3 cassette media out sensor
Switch SW1 Paper deck door-open-detection switch
SW2 Paper deck cassette 1 cassette media end switch
SW3 Paper deck cassette 1 cassette media width switch
SW82 Paper deck cassette 2 cassette media end switch
SW83 Paper deck cassette 2 cassette media width switch
SW92 Paper deck cassette 3 cassette media end switch
SW93 Paper deck cassette 3 cassette media width switch
ENWW Optional 3X500-sheet paper deck 75
Motor control
Each of the paper deck cassettes uses two motors for paper-feed and cassette lift-up operation.
Figure 1-56 Paper deck motors
Paper deck cassette lifter motor
Paper deck cassette pickup motor
Table 1-14 Paper deck motors
Component Component driven Failure
detection
Paper deck cassette 1 pickup motor M1 Paper deck cassette 1 pickup roller, paper
deck cassette 1 separation roller, and paper
deck cassette 1 feed roller
No
Paper deck cassette 1 lifter motor M2 Lifter for the paper deck cassette 1 No
Paper deck cassette 2 pickup motor M81 Paper deck cassette 2 pickup roller, paper
deck cassette 2 separation roller, and paper
deck cassette 2 feed roller
No
Paper deck cassette 2 lifter motor M82 Lifter for the paper deck cassette 2 No
Paper deck cassette 3 pickup motor M91 Paper deck cassette 3 pickup roller, paper
deck cassette 3 separation roller, and paper
deck cassette 3 feed roller
No
Paper deck cassette 3 lifter motor M92 Lifter for the paper deck cassette 3 No
76 Chapter 1 Theory of operation ENWW
Pickup-and-feed operation
The pickup-and-feed operation picks up one sheet of paper in the paper deck cassette and feeds it to
the product. The paper deck has three cassettes but each cassette performs the same operation. Paper
deck cassette 3 is used to describe the pickup-and-feed operation in this section.
Figure 1-57 Pickup-and-feed operation
M91
M92
SL91
SR1
SW1
SR92
SR93
Paper deck cassette 1
Paper deck cassette 2
Paper deck cassette 3
SW92 SW93
Table 1-15 Pickup-and-feed operation
Component Signal
Paper deck cassette 1 pickup motor M1 PAPER DECK CASSETTE 1 PICKUP MOTOR CONTROL
signal
Paper deck cassette 1 lifter motor M2 PAPER DECK CASSETTE 1 LIFTER MOTOR CONTROL
signal
Paper deck cassette 1 pickup solenoid SL01 PAPER DECK CASSETTE 1 SOLENOID signal
Paper deck cassette 1 media feed sensor SR1 PAPER DECK CASSETTE 1 MEDIA FEED signal
Paper deck cassette 1 media stack surface sensor SR2 PAPER DECK CASSETTE 1 MEDIA STACK SURFACE
signal
Paper deck cassette 1 media out sensor SR3 PAPER DECK CASSETTE 1 MEDIA OUT signal
Paper deck door-open-detection switch SW1 PAPER DECK DOOR OPEN DETECTION signal
Paper deck cassette 1 media end switch SW2 PAPER DECK CASSETTE 1 MEDIA END signal
Paper deck cassette 1 media width switch SW3 PAPER DECK CASSETTE 1 MEDIA WIDTH signal
Paper deck cassette 2 pickup motor M81 PAPER DECK CASSETTE 2 PICKUP MOTOR CONTROL
signal
ENWW Optional 3X500-sheet paper deck 77
Table 1-15 Pickup-and-feed operation (continued)
Component Signal
Paper deck cassette 2 lifter motor M82 PAPER DECK CASSETTE 2 LIFTER MOTOR CONTROL
signal
Paper deck cassette 2 pickup solenoid SL82 PAPER DECK CASSETTE 2 SOLENOID signal
Paper deck cassette 2 media feed sensor SR81 PAPER DECK CASSETTE 2 MEDIA FEED signal
Paper deck cassette 2 media stack surface sensor SR82 PAPER DECK CASSETTE 2 MEDIA STACK SURFACE
signal
Paper deck cassette 2 media out sensor SR83 PAPER DECK CASSETTE 2 MEDIA OUT signal
Paper deck cassette 2 media end switch SW82 PAPER DECK CASSETTE 2 MEDIA END signal
Paper deck cassette 2 media width switch SW83 PAPER DECK CASSETTE 2 MEDIA WIDTH signal
Paper deck cassette 3 pickup motor M91 PAPER DECK CASSETTE 3 PICKUP MOTOR CONTROL
signal
Paper deck cassette 3 lifter motor M92 PAPER DECK CASSETTE 3 LIFTER MOTOR CONTROL
signal
Paper deck cassette 3 pickup solenoid SL91 PAPER DECK CASSETTE 3 SOLENOID signal
Paper deck cassette 3 media feed sensor SR91 PAPER DECK CASSETTE 3 MEDIA FEED signal
Paper deck cassette 3 media stack surface sensor SR92 PAPER DECK CASSETTE 3 MEDIA STACK SURFACE
signal
Paper deck cassette 3 media out sensor SR93 PAPER DECK CASSETTE 3 MEDIA 0UT signal
Paper deck cassette 3 media end switch SW92 PAPER DECK CASSETTE 3 MEDIA END signal
Paper deck cassette 3 media width switch SW93 PAPER DECK CASSETTE 3 MEDIA WIDTH signal
Cassette media-size detection and cassette-presence detection
The paper deck detects the size of the paper loaded in the paper deck cassette by monitoring the
paper deck cassette media end switch and the paper deck cassette media width switch. It also detects
the presence of cassette by monitoring the switches. The paper deck controller notifies the formatter
through the DC controller when it determines a cassette is absent.
Table 1-16 Cassette media-size detection and cassette-presence detection (3X500-sheet paper
deck)
Paper size 3X500-sheet paper deck
Cassette media width sensor
3X500-sheet paper deck
Cassette media end switch
Top switch Center switch Bottom switch Top switch Center switch Bottom switch
Executive Off On On On On On
Letter Off Off On On On On
A5 On On Off On On On
78 Chapter 1 Theory of operation ENWW
Table 1-16 Cassette media-size detection and cassette-presence detection (3X500-sheet paper
deck) (continued)
B5 Off On Off On On On
A4 OffOffOff OnOnOn
Ledger Off Off On Off Off On
Legal On On Off Off Off On
B4 Off On Off Off Off On
A3 Off Off Off Off Off On
A4-R NOTE: The product cannot detect the paper size of A4-R and Letter-R. If A4-R or Letter-R sized paper is
loaded to the cassette, A5 size is notified to the formatter.
Letter-R
Universal On On Off Off On On
Cassette absent Off Off Off Off Off Off
Cassette lift-up operation
The cassette lift-up operation keeps the surface of the paper stack at the pickup position whenever the
following occurs:
●Product power is turned on
●Cassette is installed
●Stack surface in the cassette lowers
ENWW Optional 3X500-sheet paper deck 79
The paper deck cassette media-out sensor detects the presence of paper in the paper deck cassette.
Paper deck cassette 3 is used to describe the Cassette lift-up operation in this section.
Figure 1-58 Cassette lift-up operation
M92
SR92
SR93
Lifter
Lifting plate
Paper deck cassette 3 lifter motor
Paper deck cassette 3 media stack surface sensor flag
Paper deck cassette 3 media out
sensor flag
Paper deck cassette 3 media stack surface sensor
Paper deck cassette 3 media out sensor
Paper deck cassette 1
Paper deck cassette 2
Paper deck cassette 3
80 Chapter 1 Theory of operation ENWW
Jam detection
The paper deck uses the following sensors to detect the presence of paper and to check whether paper
is being fed correctly or has jammed.
●Paper deck cassette 1 media feed sensor (SR1)
●Paper deck cassette 2 media feed sensor (SR81)
●Paper deck cassette 3 media feed sensor (SR91)
Figure 1-59 Jam detection
SR1
SR81
SR91
The paper deck detects the following jams.
●Paper deck no pick jam 1
The paper deck cassette 1 media feed sensor does not detect the leading edge of paper within a
specified period after the paper deck cassette 2 media feed sensor detects the leading edge. The
paper deck cassette 2 media feed sensor does not detect the leading edge of paper within a
specified period after the paper deck cassette 3 media feed sensor detects the leading edge.
●Paper deck no pick jam 2
The paper deck cassette 1 media feed sensor does not detect the leading edge of paper within a
specified period, including a retry, after the paper deck cassette 1 pickup solenoid has turned on.
The paper deck cassette 2 media feed sensor does not detect the leading edge of paper within a
specified period, including a retry, after the paper deck cassette 2 pickup solenoid has turned on.
The paper deck cassette 3 media feed sensor does not detect the leading edge of paper within a
specified period, including a retry, after the paper deck cassette 3 pickup solenoid has turned on.
●Paper deck residual paper jam
ENWW Optional 3X500-sheet paper deck 81
Any one of the following sensors detects a presence of paper after the automatic delivery is
performed when the printer is turned on or when the door is closed.
◦Paper deck cassette 1 media feed sensor
◦Paper deck cassette 2 media feed sensor
◦Paper deck cassette 3 media feed sensor
●Paper deck door open jam
A paper deck door open is detected during a paper-feed operation.
●Automatic Delivery
The paper deck automatically clears the paper if any one of the following sensors detects the
residual paper during the initial sequence after the printer is turned on or after the door is closed.
◦Paper deck cassette 1 media feed sensor
◦Paper deck cassette 2 media feed sensor
◦Paper deck cassette 3 media feed sensor
82 Chapter 1 Theory of operation ENWW
2 Removal and replacement
●Introduction
●Removal and replacement strategy
●Electrostatic discharge
●Required tools
●Service approach
●Removal and replacement procedures
ENWW 83
Introduction
This chapter describes the removal and replacement of field-replaceable units (FRUs) only.
Replacing FRUs is generally the reverse of removal. Occasionally, notes and tips are included to
provide directions for difficult or critical replacement procedures.
HP does not support repairing individual subassemblies or troubleshooting to the component level.
Note the length, diameter, color, type, and location of each screw. Be sure to return each screw to its
original location during reassembly.
Incorrectly routed or loose wire harnesses can interfere with other internal components and can become
damaged or broken. Frayed or pinched harness wires can be difficult to find. When replacing wire
harnesses, always use the provided wire loops, lance points, or wire-harness guides and retainers.
Removal and replacement strategy
WARNING! Turn the product off, wait 5 seconds, and then remove the power cord before
attempting to service the product. If this warning is not followed, severe injury can result, in addition to
damage to the product. The power must be on for certain functional checks during troubleshooting.
However, disconnect the power supply during parts removal.
Never operate or service the product with the protective cover removed from the laser/scanner
assembly. The reflected beam, although invisible, can damage your eyes.
The sheet-metal parts can have sharp edges. Be careful when handling sheet-metal parts.
CAUTION: Do not bend or fold the flat flexible cables (FFCs) during removal or installation. Also, do
not straighten pre-folds in the FFCs. You must fully seat all FFCs in their connectors. Failure to fully seat
an FFC into a connector can cause a short circuit in a PCA.
NOTE: To install a self-tapping screw, first turn it counterclockwise to align it with the existing thread
pattern, and then carefully turn it clockwise to tighten. Do not overtighten. If a self-tapping screw-hole
becomes stripped, repair the screw-hole or replace the affected assembly.
TIP: For clarity, some photos in this chapter show components removed that would not be removed to
service the product. If necessary, remove the components listed at the beginning of a procedure before
proceeding to service the product.
Electrostatic discharge
CAUTION: Some parts are sensitive to electrostatic discharge (ESD). Look for the ESD reminder
when removing product parts. Always perform service work at an ESD-protected workstation or mat, or
use an ESD strap. If an ESD workstation, mat, or strap is not available, ground yourself by touching the
sheet-metal chassis before touching an ESD-sensitive part.
Protect the ESD-sensitive parts by placing them in ESD pouches when they are out of the product.
84 Chapter 2 Removal and replacement ENWW
Required tools
●#2 Phillips screwdriver with a magnetic tip and a 152-mm (6-inch) shaft length
●Small flat blade screwdriver
●Needle-nose pliers
●ESD mat or ESD strap (if one is available)
●Portable USB storage device (USB thumbdrive); for firmware upgrade
●Penlight (optional)
CAUTION: Always use a Phillips screwdriver (callout 1). Do not use a pozidrive screwdriver
(callout 2) or any motorized screwdriver. These can damage screws or screw threads.
Figure 2-1 Phillips and pozidrive screwdriver comparison
ENWW Required tools 85
Service approach
Before performing service
●Remove all media from the product.
●Turn off the power using the power switch.
●Unplug the power cable and interface cable or cables.
●Place the product on an ESD workstation or mat, or use an ESD strap (if one is available). If an
ESD workstation, mat, or strap is not available, ground yourself by touching the sheet-metal
chassis before touching an ESD-sensitive part.
●Remove the print cartridges. See Print cartridges on page 87.
●Remove the tray cassette or cassettes.
After performing service
●Plug in the power cable.
●Reinstall the print cartridges.
●Reinstall the tray cassette or cassettes.
●If the 1 x 500-sheet paper feeder or optional 3 x 500-sheet paper feeder was removed for
service, place the product on the feeder or feeders. Engage the feeder tray locks to secure the
feeder or feeders to the product.
Post-service test
Perform the following test to verify that the repair or replacement was successful.
Print-quality test
1. Verify that you have completed the necessary reassembly steps.
2. Make sure that the tray contains clean, unmarked paper.
3. Attach the power cord and interface cable or interface cables, and then turn on the product.
4. Verify that the expected startup sounds occur.
5. Print a configuration page, and then verify that the expected printing sounds occur.
6. Print a demo page, and then verify that the print quality is as expected.
7. Send a print job from the host computer, and then verify that the output meets expectations.
8. If necessary, restore any customer-specified settings.
9. Clean the outside of the product with a damp cloth.
86 Chapter 2 Removal and replacement ENWW
Removal and replacement procedures
NOTE: The following assemblies are Customer Self Repair (CSR) components. Go to Covers
on page 111 or Main assemblies on page 130 for information about removing service assemblies.
Print cartridges
When a print cartridge approaches the end of its estimated useful life, the control panel displays a
message recommending that you order a replacement. The product can continue to print using the
current print cartridge until the control panel displays a message instructing you to replace the
cartridge, unless you have selected the option to override the message by using the Supply Settings
menu.
NOTE: Cartridge life remaining is used to determine if a supply is near or at estimated end of life.
Cartridge life remaining is approximate only, and varies depending on types of documents printed and
other factors.
The product uses four colors and has a different print cartridge for each color: black (K), magenta (M),
cyan (C), and yellow (Y).
You can replace a print cartridge when the print quality is no longer acceptable. The control-panel
message also indicates the color of the cartridge that has reached the end of its estimated useful life.
Replacement instructions are provided on the label on the print cartridge.
CAUTION: If toner gets on clothing, wipe it off with a dry cloth and wash the clothes in cold water.
Hot water sets toner into fabric.
NOTE: Information about recycling used print cartridges is contained in the print-cartridge box.
Replace print cartridges
1. Open the front door. Make sure that the door is completely open.
ENWW Removal and replacement procedures 87
2. Grasp the handle of the used print cartridge and pull out to remove.
3. Remove the new print cartridge from its protective bag.
NOTE: Be careful not to damage the memory tag on the print cartridge.
88 Chapter 2 Removal and replacement ENWW
4. Grasp both sides of the print cartridge and distribute the toner by gently rocking the print
cartridge.
5. Remove the orange protective cover from the print cartridge. Place the protective cover on the
used print cartridge to protect it during shipping.
CAUTION: Avoid prolonged exposure to light.
Do not touch the green roller. Doing so can damage the cartridge.
NOTE: Store the used print cartridge in the protective bag removed from the replacement
cartridge. Information about recycling used print cartridges is contained in the print-cartridge box.
6. Align the print cartridge with its slot and insert the print cartridge until it clicks into place.
ENWW Removal and replacement procedures 89
7. Close the front door.
90 Chapter 2 Removal and replacement ENWW
Toner-collection unit
NOTE: The toner-collection unit (TCU) is designed for a single use. Do not try to empty the toner-
collection unit and reuse it. To recycle a discarded toner-collection unit, follow the instructions that come
with a replacment toner-collection unit.
1. Open the TCU access door (callout 1) on the product back side.
2. Grasp the top of the TCU (callout 2), and then remove it from the product.
Figure 2-2 Remove the toner-collection unit (1 of 3)
2
1
3. Remove the plug from the discarded TCU.
Figure 2-3 Remove the toner-collection unit (2 of 3)
ENWW Removal and replacement procedures 91
4. Install the plug onto the discarded TCU before putting it into the box and mailing it for recycling.
Figure 2-4 Remove the toner-collection unit (3 of 3)
92 Chapter 2 Removal and replacement ENWW
Fuser
CAUTION: The fuser might be hot. Allow enough time after turning off the product power for the
fuser to cool.
1. Open the right-door assembly.
2. Grasp the handles and squeeze the blue release levers (callout 1).
Figure 2-5 Remove the fuser
2
1
3. Pull the fuser (callout 2) straight out of the product to remove it.
Reset the New Fuser Kit setting at the control panel
NOTE: Use this procedure to reset the internal page count if a replacement fuser is installed.
1. At the control panel, press the Home button .
2. Open the following menus:
●Administration
●Manage Supplies
●Reset Supplies
●New Fuser Kit
3. Use the Down arrow button to highlight the Yes item, and then press OK to select it.
ENWW Removal and replacement procedures 93
Pickup roller (Tray 1)
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause paper pickup problems.
1. Open Tray 1 (callout 1), and then remove the pickup roller cover (callout 2).
Figure 2-6 Remove the pickup roller (Tray 1) (1 of 2)
1 2
2. Spead out the pickup roller retainers (callout 1) until both sides unlatch, and then remove the
pickup roller (callout 2).
Reinstallation tip When you reinstall the roller, make sure that the roller snaps into place
Figure 2-7 Remove the pickup roller (Tray 1) (2 of 2)
2
1 1
94 Chapter 2 Removal and replacement ENWW
Separation pad (Tray 1)
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause paper pickup problems.
1. Open Tray 1 (callout 1), and then remove the pickup roller cover (callout 2).
Figure 2-8 Remove the separation pad (Tray 1) (1 of 4)
1 2
2. Take out the tool (callout 2) supplied with a new separation pad (callout 1).
Figure 2-9 Remove the separation pad (Tray 1) (2 of 4)
1
2
ENWW Removal and replacement procedures 95
3. Insert the tool under the separation pad.
Figure 2-10 Remove the separation pad (Tray 1) (3 of 4)
4. Rotate the top of the tool away from the product to release the separation pad, and then remove
the tool and the separation pad together.
Figure 2-11 Remove the separation pad (Tray 1) (4 of 4)
Reinstallation tip You do not need to use the tool to install the new separation pad. Press the new
pad with your hand until it snaps into place and engages with the engine.
96 Chapter 2 Removal and replacement ENWW
Separation roller assembly (Tray 2)
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause paper pickup problems.
1. Remove Tray 2 from the product.
2. Open the right-door assembly.
3. On the separation roller assembly, slide the lever (callout 1) toward the unlocked icon until it
clicks into the unlocked position.
Figure 2-12 Remove the separation roller assembly (Tray 2) (1 of 2)
1
4. Pull the separation roller assembly up and remove it from the product.
Reinstallation tip When you install the separation roller assembly, make sure that it snaps into
the locked postion.
Figure 2-13 Remove the separation roller assembly (Tray 2) (2 of 2)
ENWW Removal and replacement procedures 97
Pickup roller (Tray 2)
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause paper pickup problems.
1. Open Tray 2.
2. Open the right-door assembly.
3. Remove the separation roller assembly (see Separation roller assembly (Tray 2) on page 97)
4. Lift one of the two levers (callout 1) on either side of the pickup roller, and then push the right side
of the roller in the direction of the arrow.
Figure 2-14 Remove the pickup roller (Tray 2)
1
5. Remove the pickup roller.
Reinstallation tip Insert the left side of the roller into the product first. Make sure that the
replacement roller snaps into place.
98 Chapter 2 Removal and replacement ENWW
Pickup roller, separation roller, and feed roller (1 x 500-sheet and
3 x 500-sheet paper feeders)
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause paper pickup problems.
TIP: You do not have to separate the product from the feeder to remove these rollers.
1. Remove the Tray 3 or Tray 4/5/6 cassette from the product, and then locate the rollers on the
right-hand side of the tray cavity.
Figure 2-15 Remove the 1 x 500 or 3 x 500 rollers (1 of 2)
ENWW Removal and replacement procedures 99
2. Release three tabs, and then pull the rollers in the direction of the arrow.
Figure 2-16 Remove the 1 x 500 or 3 x 500 rollers (2 of 2)
Reinstallation tip When you reinstall the rollers, make sure that the rollers snap into place.
100 Chapter 2 Removal and replacement ENWW
Secondary transfer roller
CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the
roller can cause image quality problems.
NOTE: If the secondary transfer roller is replaced, HP recommends that the ITB be replaced also. If
both components are replaced at the same time, you must use the control-panel menus to reset the
Transfer Kit menu item. See Reset the New Transfer Kit setting at the control panel on page 104.
1. Open the right-door assembly.
2. Grasp one of the blue round features (callout 1) on either end of the transfer roller, and then lift
the transfer roller (callout 2) off of the product.
Figure 2-17 Remove the transfer roller
2
1
TIP: Place the new roller assembly in place with the roller gear (callout 1) on the right side, and
then press down to ensure that the roller shaft snaps securely in the roller clasps.
1
ENWW Removal and replacement procedures 101
Intermediate transfer belt (ITB)
CAUTION: Do not touch the black-plastic belt. Skin oils and fingerprints on the belt can cause print-
quality problems. Always place the ITB on a flat surface in a safe and protected location.
NOTE: If the ITB assembly is replaced, HP recommends that the secondary transfer roller be replaced
also. If both components are replaced at the same time, you must use the control-panel menus to reset
the Transfer Kit menu item. See Reset the New Transfer Kit setting at the control panel
on page 104.
1. Open the right-door assembly.
2. Use both hands to grasp the blue levers (callout 1), apply slight downward pressure, and pull the
ITB toward you at a downward angle.
Figure 2-18 Remove the intermediate transfer belt (1 of 3)
1
102 Chapter 2 Removal and replacement ENWW
3. Pull the ITB out of the product until two large handles expand along the right and left side of the
ITB.
Figure 2-19 Remove the intermediate transfer belt (2 of 3)
4. Grasp the large handles on the ITB, pull it straight out of the product until it stops, and then pull up
to remove it from the product.
CAUTION: The ITB is a sensitive component. Be careful when handling the ITB so that it is not
damaged. Always place the ITB in a safe and protected location.
Figure 2-20 Remove the intermediate transfer belt (3 of 3)
Reinstallation tip If you are installing a replacement ITB, make sure that you remove all of the
packing tape and the protective cover sheet.
ENWW Removal and replacement procedures 103
Reset the New Transfer Kit setting at the control panel
NOTE: Use this procedure to reset the internal page count if a replacement ITB and secondary
transfer roller are installed.
1. At the control panel, press the Home button .
2. Open the following menus:
●Administration
●Manage Supplies
●Reset Supplies
●New Transfer Kit
3. Use the Down arrow button to highlight the Yes item, and then press OK to select it.
104 Chapter 2 Removal and replacement ENWW
Formatter PCA
CAUTION: ESD sensitive component.
Do not replace the laser scanner and the formatter PCA at the same time. The settings for the laser
scanner are stored in the formatter RAM. When you install a new laser scanner, it reads the settings
from the formatter.
Do not replace the DC controller PCA and the formatter PCA at the same time. The settings for the DC
Controller PCA are stored in the formatter RAM. When you install a new DC Controller PCA, it reads
the settings from the formatter.
NOTE: If possible, print a configuration page before replacing the formatter. You might need to
transfer the serial number and the page count information to the new formatter.
1. Disconnect communication cables (if installed).
CAUTION: Make sure that the product power is off and that the power cord is unplugged.
Figure 2-21 Remove the formatter (1 of 2)
ENWW Removal and replacement procedures 105
2. Loosen two thumb screws, and then pull the formatter straight out and away from the product to
remove it.
Figure 2-22 Remove the formatter (2 of 2)
3. Firmly pull the formatter from the product. Place the formatter on a clean, flat, grounded surface.
Reinstallation tip If the formatter PCA was replaced, print a configuration page and make
sure that the serial number and page count information were transfered to the formatter PCA. If
they were not, use the Service menu to reset these values.
106 Chapter 2 Removal and replacement ENWW
Hard Drive
Before proceeding, remove the following components:
●Formatter PCA. See Formatter PCA on page 105.
Identify the hard drive type
❑Encrypted hard-disk drive (callout 1)
1
❑Solid-state hard drive (callout 1)
1
ENWW Removal and replacement procedures 107
Remove the encrypted HDD
NOTE: If you are installing a replacement hard drive, you must reinstall the product firmware. See
Product updates on page 547.
1. Disconnect two connectors (callout 1).
Figure 2-23 Remove the encrypted HDD (1 of 3)
1
2. Release one tab (callout 1), and then slightly separate the HDD support arm from the PCA.
Figure 2-24 Remove the encrypted HDD (2 of 3)
1
108 Chapter 2 Removal and replacement ENWW
3. Rotate the HDD up and away from the PCA, and then slide it as shown below to remove it.
Figure 2-25 Remove the encrypted HDD (3 of 3)
1
2
Remove the solid-state hard drive
NOTE: If you are installing a replacement hard drive, you must reinstall the product firmware. See
Product updates on page 547.
1. Release the hard drive lock.
Figure 2-26 Remove the solid-state hard drive (1 of 3)
ENWW Removal and replacement procedures 109
2. Remove the lock from the PCA.
Figure 2-27 Remove the solid-state hard drive (2 of 3)
3. Disconnect the solid-state PCA from the formatter PCA, and then remove it.
Figure 2-28 Remove the solid-state hard drive (3 of 3)
110 Chapter 2 Removal and replacement ENWW
Covers
Identification and location
Figure 2-29 External panels, covers, and doors
1
2
3
4
5
6
7
9
8
Table 2-1 External panels, covers, and doors
Item Description Item Description
1 Rear-right cover (see Right-rear cover
on page 119)
6 Top cover (see Top cover on page 121)
ENWW Removal and replacement procedures 111
Table 2-1 External panels, covers, and doors (continued)
Item Description Item Description
2 Right-door assembly (see Right-door assembly
on page 126)
7 Left cover (see Left cover on page 115)
3 Right-front cover and control-panel assembly (see
Right-front cover and control-panel assembly
on page 113)
8 Rear cover (see Rear cover on page 116)
4 Front-door assembly (see Front-door assembly
on page 123)
9 Toner collection unit access door (see Toner
collection unit access door on page 117)
5 Tray 2 cassette
112 Chapter 2 Removal and replacement ENWW
Right-front cover and control-panel assembly
1. Open the front door and the right door.
2. Remove two screws (callout 1).
Figure 2-30 Remove the right-front cover and control-panel assembly (1 of 3)
1
3. Release 3 tabs (callout 1) on the right side of the assembly.
Figure 2-31 Remove the right-front cover and control-panel assembly (2 of 3)
1
ENWW Removal and replacement procedures 113
Release two tabs on the top of
the assembly also.
4. Support the assembly, release one cable retainer (callout 1), and then disconnect two connectors
(callout 2). Remove the assembly.
Figure 2-32 Remove the right-front cover and control-panel assembly (3 of 3)
1
2
114 Chapter 2 Removal and replacement ENWW
Left cover
1. Remove Tray 2 from the product.
2. Open the front door.
3. Remove three screws (callout 1). Starting from the left side of the cover, release six tabs (callout 2),
and then remove the cover from the product.
Figure 2-33 Remove the left cover
2
1
2
TIP: Opening the toner-collection door might make it easier to release the tabs on the left side of
the cover.
Reinstallation tip If the front door will not close after the left cover has been reinstalled, verify that
the two tabs on the right side of the cover have been aligned correctly with the product chassis.
ENWW Removal and replacement procedures 115
Rear cover
Remove the rear cover
▲Remove five screws (callout 1), and then remove the cover (callout 2) from the product.
Figure 2-34 Remove the rear cover
1
2
116 Chapter 2 Removal and replacement ENWW
Toner collection unit access door
1. Open the toner collection unit access door (callout 1), remove the toner collection unit, and then
release the link arm (callout 2) on the left side of the door.
Figure 2-35 Remove the toner collection unit access door (1 of 3)
1
2
2. Partially close the door so that the right link arm (callout 1) can clear the stop (callout 2) on the
door, and then disengage the link arm from the door.
CAUTION: Do not disconnect the right-hand link arm when the door is completely open. Doing
so can disconnect the link arm spring.
Figure 2-36 Remove the toner collection unit access door (2 of 3)
1
2
ENWW Removal and replacement procedures 117
3. Rotate the access door down 90 degrees (callout 1), and then pull on the right side of the door
(callout 2) to remove the access door.
Figure 2-37 Remove the toner collection unit access door (3 of 3)
1
2
118 Chapter 2 Removal and replacement ENWW
Right-rear cover
1. Remove the rear cover. See Rear cover on page 116.
2. Open the right-door assembly.
3. Remove two screws (callout 1), release one tab (callout 2), and then remove the cover.
CAUTION: The ground spring on the back of the cover can easily be dislodged. Be careful not
to lose it. See Reinstall the right-rear cover on page 120.
Figure 2-38 Remove the right-rear cover
1
2
ENWW Removal and replacement procedures 119
Reinstall the right-rear cover
▲Make sure that the ground spring (callout 1) is correctly installed before you reinstall the right-rear
cover.
Figure 2-39 Right-rear cover ground spring
1
120 Chapter 2 Removal and replacement ENWW
Top cover
Before proceeding, remove the following components:
●Right-front cover and control-panel assembly. See Right-front cover and control-panel assembly
on page 113.
●Left cover. See Left cover on page 115.
●Remove the rear cover. See Rear cover on page 116.
●Right-rear cover. See Right-rear cover on page 119.
Remove the top cover
1. Open the right-door assembly, and then remove four screws (callout 1).
Figure 2-40 Remove the top cover (1 of 2)
1
1
2. Open the toner-collection door.
ENWW Removal and replacement procedures 121
3. Release two tabs (callout 1), and then remove the cover (callout 2).
Figure 2-41 Remove the top cover (2 of 2)
1
2
122 Chapter 2 Removal and replacement ENWW
Front-door assembly
1. Remove the control panel. See Right-front cover and control-panel assembly on page 113.
2. Open the front door.
3. Remove one screw (callout 1) and the inner cover rail mount (callout 2).
CAUTION: As shown in Figure 2-43 Remove the front-door assembly (2 of 4) on page 123,
when removing the inner cover rail mount (callout 3), hold down the inner cover (callout 4) with
one hand to prevent it from springing back at the product.
Figure 2-42 Remove the front-door assembly (1 of 4)
1
2
Figure 2-43 Remove the front-door assembly (2 of 4)
3
4
ENWW Removal and replacement procedures 123
4. Close the inner cover, and then release two tabs on each stopper (callout 1) with a small flat-blade
screwdriver (callout 2).
Figure 2-44 Remove the front-door assembly (3 of 4)
1
NOTE: Each tab is at the end of the stopper that is closest to the product.
1
2
124 Chapter 2 Removal and replacement ENWW
5. Position the door as shown below (callout 1), and then slide the front-door assembly in the
direction that the arrow indicates to remove it from the product.
Figure 2-45 Remove the front-door assembly (4 of 4)
1
ENWW Removal and replacement procedures 125
Right-door assembly
Remove the following components:
●Rear cover (see Rear cover on page 116)
●Right rear cover (see Right-rear cover on page 119)
1. Open the right-door assembly
2. Remove one screw (callout 1), release the link arm (callout 2), and then disconnect two connectors
(callout 3).
NOTE: The link arm is spring loaded and retracts into the product.
Figure 2-46 Remove the right-door assembly (1 of 6)
2
1
3
126 Chapter 2 Removal and replacement ENWW
Connectors J152 and J112 on the DC Controller.
3. Carefully release one tab (callout 1), and then remove the cable cover (callout 2).
Figure 2-47 Remove the right-door assembly (2 of 6)
2
1
4. Release one tab (callout 1), and then remove the guide (callout 2).
TIP: Release the wire harnesses from the guide as you remove it.
Figure 2-48 Remove the right-door assembly (3 of 6)
2
1
ENWW Removal and replacement procedures 127
5. Disconnect two connectors (callout 1).
Figure 2-49 Remove the right-door assembly (4 of 6)
1
6. Remove one screw (callout 1), and then release the link arm (callout 2).
Figure 2-50 Remove the right-door assembly (5 of 6)
2
1
128 Chapter 2 Removal and replacement ENWW
7. Remove two screws (callout 1), remove the hinge (callout 2), and then slide the right-door
assembly (callout 3) to the left to remove it.
Figure 2-51 Remove the right-door assembly (6 of 6)
12
3
ENWW Removal and replacement procedures 129
Main assemblies
TIP: For clarity, some photos in this chapter show components removed that would not be removed to
service the product. If necessary, remove the components listed at the beginning of a procedure before
proceeding to service the product.
Formatter case
Before proceeding, remove the following components:
●Formatter PCA. See Formatter PCA on page 105.
●Left cover. See Left cover on page 115.
●Rear cover. See Rear cover on page 116.
Remove the formatter case
1. Remove two screws (callout 1).
Figure 2-52 Remove the formatter case assembly (1 of 2)
1
130 Chapter 2 Removal and replacement ENWW
2. Remove nine screws (callout 1), and then slide the formatter case unit (callout 2) away from the
DC controller to remove it.
Figure 2-53 Remove the formatter case assembly (2 of 2)
1
ENWW Removal and replacement procedures 131
Laser/scanner assembly
CAUTION: Do not replace the laser scanner and the formatter PCA at the same time. The settings for
the laser scanner are stored in the formatter RAM. When you install a new laser scanner, it reads the
settings from the formatter.
Before proceeding, remove the following components:
●Tray 2
●Left cover. See Left cover on page 115.
Remove the laser/scanner assembly
1. Open the front door.
2. On the left side of the product, pinch and remove the fan duct (callout 1), and then disconnect the
two flat cables (callout 2).
Figure 2-54 Remove the laser/scanner assembly (1 of 4)
2 1
132 Chapter 2 Removal and replacement ENWW
3. Release one tab (callout 1), remove the stopper (callout 2), and then disconnect one connector
(callout 3).
Figure 2-55 Remove the laser/scanner assembly (2 of 4)
1
2
3
4. Release one tab (callout 1), and then slide the cable guide (callout 2) in the direction that the
arrow indicates.
5. Remove the cable guide (callout 2) and the flat cables (callout 3) together, and then remove one
spring (callout 4).
Figure 2-56 Remove the laser/scanner assembly (3 of 4)
43
21
ENWW Removal and replacement procedures 133
6. While holding up the handle (callout 1), pull the laser/scanner (callout 2) up slightly and then out
of the product.
CAUTION: Do not touch the protective glass strip on top of the assembly.
Figure 2-57 Remove the laser/scanner assembly (4 of 4)
1 2
Reinstallation tip Align the assembly with the guides on the left side of the opening when
reinstalling the assembly.
Align the pin on the bottom of the assembly with the hole in the product when reinstalling the
assembly. After pushing the assembly into the product, you might have to pull the assembly slightly
forward to seat the pin in the hole.
134 Chapter 2 Removal and replacement ENWW
Paper pickup assembly
Before proceeding, remove the following components:
●Tray 2 cassette.
●Tray 2 separation roller assembly. See Separation roller assembly (Tray 2) on page 97.
●ITB. See Intermediate transfer belt (ITB) on page 102.
Remove the paper pickup assembly
1. Open the right door, pull out one tab (callout 1), pull the bottom of the cable cover out, and then
pull up to remove the cable cover (callout 2).
Figure 2-58 Remove the paper pickup assembly (1 of 3)
2
1
ENWW Removal and replacement procedures 135
2. Disconnect four connectors (callout 1).
NOTE: The connectors might be hidden behind the assembly.
Figure 2-59 Remove the paper pickup assembly (2 of 3)
1
3. Pull out one tab (callout 1), and then slide the guide (callout 2) to the right to remove it.
Figure 2-60 Remove the paper pickup assembly (3 of 3)
1
2
136 Chapter 2 Removal and replacement ENWW
4. Remove two screws (callout 1), move the registration sensor flag (callout 2) to the up position, and
then pull the paper pickup assembly (callout 3) toward you to remove it.
Figure 2-61 Remove the paper pickup assembly (4 of 4)
1
2
3
ENWW Removal and replacement procedures 137
Reinstall the paper pickup assembly
Use the steps below to reinstall the paper pickup assembly. If you are installing a replacement
assembly, also see Installing a replacement paper pickup assembly on page 140 after completing
these steps.
1. When reassembling the paper pickup assembly (callout 1), the sensor flag (callout 2) is in the
way. Be sure to hold up the sensor flag when reassembling.
Figure 2-62 Reinstall the paper pickup assembly
2
1
138 Chapter 2 Removal and replacement ENWW
2. Make sure that the sensor flag is correctly installed, and that the flag moves properly after
reassembling the paper pickup assembly.
Figure 2-63 Paper pickup assembly sensor flag correctly installed
Figure 2-64 Paper pickup assembly sensor flag incorrectly installed
ENWW Removal and replacement procedures 139
Installing a replacement paper pickup assembly
▲Use the Service menu to reset the New Registration Roller menu item and enter the Media
Sensor Value from the replacement paper pickup assembly.
Reset the New Registration Roller menu item
a. Press the Home button .
b. Open the following menus:
●Device Maintenance
●Service
●Service Access Code
c. Use the arrow buttons to enter the access code, and then press the OK button.
d. Press the Down arrow button to highlight the New Registration Roller menu, and
then press the OK button.
e. Press the Down arrow button to highlight the Yes item, and then press the OK button.
Reset the Media Sensor Value
a. Press the Home button .
b. Open the following menus:
●Device Maintenance
●Service
●Service Access Code
c. Use the arrow buttons to enter the access code, and then press the OK button.
140 Chapter 2 Removal and replacement ENWW
d. Press the Down arrow button to highlight the Media Sensor Value menu, and then
press the OK button.
Figure 2-65 Media sensor value label
e. Use the arrow buttons to enter the media sensor value found on the replacement assembly.
f. Press the OK button to save to save the value.
ENWW Removal and replacement procedures 141
Registration sensor assembly
Before proceeding, remove the following components: