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HP Color LaserJet Enterprise CM4540 MFP Series Service Manual

Office mfp hp color laserjet enterprise cm4540 mfp series.
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COLOR LASERJET ENTERPRISE CM4540
MFP SERIES

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Troubleshooting

   Related Manuals for HP Color LaserJet Enterprise CM4540 MFP Series

   Summary of Contents for HP Color LaserJet Enterprise CM4540 MFP Series

  • Page 1: Service Manual

    COLOR LASERJET ENTERPRISE CM4540 MFP SERIES Service Manual...

  • Page 3

    HP Color LaserJet Enterprise CM4540 MFP Series Service Manual...

  • Page 4

    Windows Vista® are U.S. registered services. Nothing herein should be trademarks of Microsoft Corporation. construed as constituting an additional warranty. HP shall not be liable for technical PANTONE® is Pantone, Inc's check- or editorial errors or omissions contained standard trademark for color.

  • Page 5: Conventions Used In This Guide

    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.

  • Page 6

    Conventions used in this guide ENWW...

  • Page 7: Table Of Contents

    Table of contents 1 Theory of operation ......................1 Basic operation ........................2 Sequence of operation ....................4 Engine-control system ........................ 5 DC controller ......................6 Solenoids ....................6 Clutches ....................7 Switches ....................7 Sensors ..................... 8 Motors ...................... 9 Fans ........................

  • Page 8: Table Of Contents

    Step 4: Development ................28 Step 5: Primary transfer ................29 Step 6: Secondary transfer ................ 29 Step 7: Separation ................... 30 Step 8: Fusing ..................30 Step 9: ITB cleaning ................. 31 Step 10: Drum cleaning ................31 Print cartridge ......................31 Developing-roller engagement and disengagement .............

  • Page 9: Table Of Contents

    Document feeder/scanner motor and fan control ............71 Legal detection sensor sequence ................72 Fan timing sequence ....................72 Optical assembly operation ..................73 Image data path ..................... 73 Document feeder/scanner paper path and sensors ............74 Document feeder pick mechanism ................75 3-bin stapling mailbox ......................

  • Page 10: Table Of Contents

    Pickup roller (Tray 1) ..................... 114 Reinstalling the pickup roller (Tray 1) ............... 117 Secondary transfer roller ..................118 Reinstall the transfer roller ............... 119 Intermediate transfer belt (ITB) ................. 120 Standard output bin ....................123 Output bin bezel ....................124 Remove the output bin bezel ..............

  • Page 11: Table Of Contents

    Remove the ASY-TRY-SP (tray assembly) ............ 155 ASY-FRM-RE-FEED-SP (internal assembly) ..............157 Remove ASY-FRM-RE-FEED-SP (internal assembly) ........157 ASY-PBA-RELAY-SB (document feeder PCA) ............... 159 Remove the ASY-PBA-RELAY-SB (document feeder PCA) ....... 159 ASM-IF-SP (document feeder cable) ................. 160 Remove the ASM-IF-SP (document feeder cable) ......... 161 ASY-HNG-L-SP (document feeder left hinge) ..............

  • Page 12: Table Of Contents

    S-ASSY-INV (inverter) ..................... 188 Remove the S-ASSY-INV (inverter) ............. 188 S-FAN-MFB-30E-05A-006 (inverter fan) ..............190 Remove the S-FAN-MFB-30E-05A-006 (inverter fan) ........190 ASSY-CRG-UNIT-IR4068 (optical assembly) .............. 191 Remove the ASSY-CRG-UNIT-IR4068 (optical assembly) ......191 S-ASSY-MOTOR-UNIT (motor assembly) ..............195 Remove the S-ASSY-MOTOR-UNIT (motor assembly) ........195 S-FAN-D06037600G-001 (scanner fan) ..............

  • Page 13: Table Of Contents

    Image scanner power supply unit (PSU) ..............237 Remove the image scanner supply unit (PSU) and fan ......... 238 Interconnect board (ICB) ..................239 Remove the ICB ..................239 DC controller PCA only ..................241 Remove the DC controller PCA only ............241 Low-voltage power supply (LVPS) ................

  • Page 14: Table Of Contents

    ITB motor ......................292 Remove the ITB motor ................292 Main-drive assembly ....................293 Remove the main-drive assembly .............. 294 Reinstall the main-drive assembly ..........298 Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) ........303 Front door (optional paper feeder) ................303 Rear cover (optional paper feeder) ................

  • Page 15: Table Of Contents

    Remove the lifter-drive assembly (500-sheet paper feeder) ......330 Pickup motor assembly (500-sheet paper feeder) ............331 Remove the pickup motor (500-sheet paper feeder) assembly ...... 331 Controller PCA (500-sheet paper feeder) ..............332 Remove the controller PCA (500-sheet paper feeder) ........332 Stapling mailbox ........................

  • Page 16: Table Of Contents

    Pre-troubleshooting checklist ..............367 Troubleshooting flowchart ............... 369 Power subsystem ....................370 Power-on checks ..................370 Power-on troubleshooting overview ..........370 Control-panel checks ..................... 372 Scanning subsystem ....................373 Tools for troubleshooting ....................... 374 Component diagnostics ..................374 LED diagnostics ..................374 LED indicators .................

  • Page 17: Table Of Contents

    Tray 4 paper size switches ............403 Tray 5 paper sensor ..............403 Tray 5 feed sensor ..............404 Tray 5 paper surface 1 and 2 sensors ........404 Tray 5 paper size switches ............405 5V laser and 24V interlock and logic switches (and power switch) 406 New ITB sensor ...............

  • Page 18: Table Of Contents

    Cleaning page ..................462 Configuration pages ................462 Configuration page ..............462 HP embedded Jetdirect page ............ 464 Embedded protocol page ............465 Finding important information on the configuration pages .... 466 Color-band test ..................466 Print-quality troubleshooting tools ................467 Repetitive defects ruler ................

  • Page 19: Table Of Contents

    20.00.00 Insufficient memory: <Device> To continue, touch “OK” ..................482 21.00.00 Page Too Complex To continue, touch “OK” ....483 30.01.YY Scanner Failure ............483 30.01.YY Scanner Failure ............483 30.01.YY Scanner Failure ............483 30.01.YY Scanner Failure ............484 30.01.YY Scanner Failure ............

  • Page 20: Table Of Contents

    47.00.XX Error ............... 495 47.01.XX Error ............... 496 47.02.XX Error ............... 496 47.03.XX Error ............... 496 47.04.XX Error ............... 497 47.06.XX Error ............... 497 47.WX.YZ Printer Calibration Failed To continue, touch “OK” ..497 48.01.XX Error ............... 498 48.03.XX Error ............... 498 48.05.XX Error ...............

  • Page 21: Table Of Contents

    59.00.YY Error To continue turn off then on ........ 512 59.0X.50 Error To continue turn off then on ........ 513 59.0X.60 Error To continue turn off then on ........ 514 60.00.0Y Tray <Y> lifting error ..........514 62.00.00 No system To continue turn off then on ......515 65.80.A1 Output accessory disconnected ........

  • Page 22: Table Of Contents

    Bad optional tray connection ............ 526 Calibrating................526 Calibration reset pending ............526 Card slot device failure To clear touch “OK” ......527 Card slot file system is full ............527 Card slot is write protected ............527 Card slot not initialized ............527 Cartridge ship mode ..............

  • Page 23: Table Of Contents

    Fuser Kit Very Low To continue, touch “OK” ....... 537 Gateways failed ..............538 Gateways OK ................. 538 Genuine HP cartridge installed ..........538 Genuine HP supply installed ............. 538 HP Secure drive disabled ............539 Incompatible <Supply> ............539 Incompatible Supplies ..............

  • Page 24: Table Of Contents

    Manually feed output stack Then touch "OK" to print second side . 545 Manually feed: <Type><Size> ..........546 Manually feed: <Type><Size> To continue, touch “OK” ....546 Manually feed: <Type><Size> To use another tray, press “OK” ..546 Moving solenoid To exit press ........... 547 Moving solenoid and motor To exit press ........

  • Page 25: Table Of Contents

    Resend external accessory firmware .......... 555 Resend Upgrade ..............555 Restoring factory settings ............555 Restricted from printing in color ..........555 RFU Load Error Send full RFU on <X> port ........556 ROM disk device failed To clear touch “OK” ......556 ROM disk file operation failed To clear touch “OK”...

  • Page 26: Table Of Contents

    Unsupported USB accessory detected Remove USB accessory ..564 Upgrade complete To continue turn off then on ......565 Upper bin full ................. 565 USB accessory needs too much power Remove USB Accessory and Turn Off then On .............. 565 USB accessory not functional ............

  • Page 27: Table Of Contents

    Jams in Tray 1, Tray 2 and internal paper path .......... 602 Jams in Tray 3, 4, and 5 ................. 603 Change jam recovery .................... 608 Paper does not feed automatically ..................609 Product feeds multiple sheets ....................610 Use manual print modes ....................... 611 Solve image-quality problems ....................

  • Page 28: Table Of Contents

    Determine the installed revision of firmware .............. 651 Perform a firmware upgrade ................... 651 Use the HP Embedded Web Server ............651 Use a USB storage device with the preboot menu ........652 Use a USB storage device with the Device Maintenance menu ..... 653 4 Parts and diagrams ......................

  • Page 29: Table Of Contents

    Appendix A Service and support ..................783 Hewlett-Packard limited warranty statement ................784 HP's Premium Protection Warranty: LaserJet print cartridge limited warranty statement ....785 Color LaserJet Fuser Kit, Transfer Kit, and Roller Kit Limited Warranty Statement ......786 Data stored on the print cartridge ................... 787 End User License Agreement ....................

  • Page 30: Table Of Contents

    Ozone production ....................799 Power consumption ....................799 Paper use ......................799 Plastics ......................... 799 HP LaserJet print supplies ..................799 Return and recycling instructions ................800 United States and Puerto Rico ..............800 Multiple returns (more than one cartridge) ........800 Single returns ................

  • Page 31: Table Of Contents

    Canadian DOC regulations ..................808 VCCI statement (Japan) ..................808 Power cord instructions ..................808 Power cord statement (Japan) ................. 808 EMC statement (China) ..................809 EMC statement (Korea) ..................809 EMI statement (Taiwan) ..................809 Laser statement for Finland ..................809 GS statement (Germany) ..................

  • Page 32

    ENWW...

  • Page 33

    List of tables Table 1-1 Sequence of operation ......................4 Table 1-2 Solenoids ..........................6 Table 1-3 Switches ..........................7 Table 1-4 Sensors ..........................8 Table 1-5 Motors ..........................9 Table 1-6 Fans ........................... 10 Table 1-7 High-voltage power supply circuits ..................12 Table 1-8 Converted DC voltages ......................15 Table 1-9 Fuser components .........................

  • Page 34

    Table 3-15 Causes and solutions for residual media jams ..............599 Table 3-16 Causes and solutions for pickup delay jams 2 ..............599 Table 3-17 Causes and solutions for pickup stationary jams ..............600 Table 3-18 Causes and solutions for duplexing reverse jams ..............600 Table 3-19 Causes and solutions for duplex repick jams ................

  • Page 35

    Table B-1 Product dimensions ......................794 Table B-2 Power requirements ......................794 Table B-3 Power consumption (average, in watts) ................794 1246 Table B-4 HP Color LaserJet Enterprise CM4540 MFP Series ..............794 Table B-5 Media registration and image placement accuracy ..............795 ENWW xxxiii...

  • Page 36

    xxxiv ENWW...

  • Page 37

    List of figures Figure 1-1 Relationship between the main product systems ................. 2 Figure 1-2 System block diagram ......................3 Figure 1-3 Engine-control system ......................5 Figure 1-4 DC controller block diagram ....................6 Figure 1-5 High-voltage power supply circuits ..................12 Figure 1-6 Low-voltage power-supply circuit ................... 14 Figure 1-7 Fuser components ........................

  • Page 38

    Figure 1-33 Three main units of the pickup, feed, and delivery system ............43 Figure 1-34 Pickup-and-feed unit ......................44 Figure 1-35 Cassette-pickup mechanism ....................45 Figure 1-36 Cassette lift mechanism ...................... 46 Figure 1-37 Multiple-feed prevention ..................... 47 Figure 1-38 Multipurpose tray pickup mechanism ................... 48 Figure 1-39 Paper-feed mechanism .......................

  • Page 39

    Figure 2-5 Remove the control panel (2 of 3) ..................100 Figure 2-6 Remove the control panel (3 of 3) ..................101 Figure 2-7 Incorrect installation of the control panel ................102 Figure 2-8 Correct installation of the control panel ................102 Figure 2-9 Remove the print cartridge (1 of 2) ..................103 Figure 2-10 Remove the print cartridge (2 of 2) ..................

  • Page 40

    Figure 2-46 Remove the ASY-CVR-FE-PICK-SP (pickup roller cover) ............126 Figure 2-47 External panels, covers, and doors; identification and location ..........127 Figure 2-48 Remove S-CVR-REAR (scanner rear cover) (1 of 2) ............... 128 Figure 2-49 Remove S-CVR-REAR (scanner rear cover) (2 of 2) ............... 128 Figure 2-50 Remove ASY-CVR-F-SP (document feeder front cover) (1 of 4) ..........

  • Page 41

    Figure 2-87 Remove the document feeder (3 of 3) ................. 152 Figure 2-88 Reinstall the document feeder .................... 152 Figure 2-89 Remove the ASY-CVR-FE-FEED-SP (document feeder jam-access cover) (1 of 2) ......153 Figure 2-90 Remove the ASY-CVR-FE-FEED-SP (document feeder jam-access cover) (2 of 2) ......154 Figure 2-91 Remove the ASY-TRY-SP (tray assembly) (1 of 2) ..............

  • Page 42

    Figure 2-128 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (1 of 4) ..............................185 Figure 2-129 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (2 of 4) 186 Figure 2-130 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (3 of 4) 186 Figure 2-131 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (4 of 4) 187 Figure 2-132 Remove the S-ASSY-INV (inverter) (1 of 2) ................

  • Page 43

    Figure 2-168 Remove the RD sensor assembly (5 of 7) ................211 Figure 2-169 Remove the RD sensor assembly (6 of 7) ................211 Figure 2-170 Remove the RD sensor assembly (7 of 7) ................212 Figure 2-171 Remove the registration assembly (1 of 8) ................ 214 Figure 2-172 Remove the registration assembly (2 of 8) ................

  • Page 44

    Figure 2-209 Remove the DC controller PCA only ................. 242 Figure 2-210 Remove the low-voltage power supply (1 of 8) ..............243 Figure 2-211 Remove the low-voltage power supply (2 of 8) ..............244 Figure 2-212 Remove the low-voltage power supply (3 of 8) ..............244 Figure 2-213 Remove the low-voltage power supply (4 of 8) ..............

  • Page 45

    Figure 2-250 Remove the tray-pickup assembly (6 of 11) ............... 271 Figure 2-251 Remove the tray-pickup assembly (7 of 11) ............... 272 Figure 2-252 Remove the tray-pickup assembly (8 of 11) ............... 272 Figure 2-253 Remove the tray-pickup assembly (9 of 11) ............... 273 Figure 2-254 Remove the tray-pickup assembly (10 of 11) ..............

  • Page 46

    Figure 2-291 Remove the front door (optional paper feeder) (1 of 2) ............303 Figure 2-292 Remove the front door (optional paper feeder) (2 of 2) ............304 Figure 2-293 Remove the rear cover (optional paper feeder) ..............305 Figure 2-294 Remove the right-front cover (optional paper feeder) ............306 Figure 2-295 Remove the right door (optional paper feeder) (1 of 3) ............

  • Page 47

    Figure 2-332 Remove the lifter-drive assembly (500-sheet paper feeder) (2 of 2) ........330 Figure 2-333 Remove the pickup motor assembly (500-sheet paper feeder) ..........331 Figure 2-334 Remove the controller PCA (500-sheet paper feeder) ............332 Figure 2-335 Remove the stapling mailbox front cover ................333 Figure 2-336 Remove the stapling mailbox rear cover ................

  • Page 48

    Figure 3-3 Engine-test button ......................377 Figure 3-4 Manual sensor test ......................379 Figure 3-5 Test the front-door switch ....................380 Figure 3-6 Test the right door switch ....................381 Figure 3-7 Test the TOP sensor (1 of 2) ....................382 Figure 3-8 Test the TOP sensor (2 of 2) ....................382 Figure 3-9 Fuser loop 1 and 2 sensors location ..................

  • Page 49

    Figure 3-79 Yellow print-quality troubleshooting page ................459 Figure 3-80 Yellow comparison page ....................459 Figure 3-81 Black print-quality troubleshooting page ................460 Figure 3-82 Configuration page ......................463 Figure 3-83 HP embedded Jetdirect page .................... 464 Figure 3-84 Embedded protocol page ....................465 ENWW xlvii...

  • Page 50

    Figure 3-85 Repetitive defects ruler ..................... 467 Figure 3-86 Sample event log ......................571 Figure 3-87 Jam locations ........................582 Figure 3-88 Paper path sensor locations ....................583 Figure 4-1 External covers, panels, and doors ..................666 Figure 4-2 Right door assembly ......................668 Figure 4-3 Front door assembly ......................670 Figure 4-4 Internal components 1 of 7 ....................

  • Page 51

    Figure 4-38 Scanner assembly (4 of 6) ....................740 Figure 4-39 Scanner assembly (5 of 6) ....................742 Figure 4-40 Scanner assembly (6 of 6) ....................744 Figure 4-41 Document feeder assembly (1 of 5) ..................746 Figure 4-42 Document feeder assembly (2 of 5) ..................748 Figure 4-43 Document feeder assembly (3 of 5) ..................

  • Page 52

    ENWW...

  • Page 53: Theory Of Operation

    Theory of operation Basic operation ● Engine-control system ● Laser/scanner system ● Image-formation system ● Pickup, feed, and delivery system ● Jam detection ● Optional paper feeders ● Document feeder/scanner assembly ● 3-bin stapling mailbox ● ENWW...

  • Page 54: Basic Operation

    Basic operation The product routes all high-level processes through the formatter, which stores font information, processes the print image, and communicates with the host computer. The basic product operation comprises the following systems: The engine-control system, which includes the power supply and the DC controller printed circuit ●...

  • Page 55

    The document feeder/scanner receives 24 volts from the scanner power supply, which is powered by an AC line from the LVPS. The intermediate paper transport unit (IPTU) receives +24 volts and 3.3 volts from the DCC. The Stapler/Stacker receives +24 volts and the JetLink control lines for communications from the DCC. Figure 1-2 System block diagram Basic operation...

  • Page 56: Sequence Of Operation

    Sequence of operation The DC controller PCA controls the operating sequence, as described in the following table. Table 1-1 Sequence of operation Period Duration Description Waiting From the time the power is turned on, Heats the fuser sleeve in the fuser ●...

  • Page 57: Engine-control System

    Engine-control system The engine-control system receives commands from the formatter and interacts with the other main systems to coordinate all product functions. The engine-control system consists of the following components: DC controller ● Low-voltage power supply ● High-voltage power supply ●...

  • Page 58: Dc Controller

    DC controller The DC controller controls the operational sequence of the product. Figure 1-4 DC controller block diagram Motor Solenoi d Motor High-voltage power supply T ITB unit Clutch Secondary transfer roller Solenoid Cartridge Switch (Y/M/C/K) Motor Photointerrupter High-voltage DC controller power supply D Sensor Sensor...

  • Page 59: Clutches

    Table 1-2 Solenoids (continued) Component abbreviation Component name Multipurpose-tray pickup solenoid Cassette pickup solenoid Clutches Component abbreviation Component name Duplex re-pickup clutch Switches Table 1-3 Switches Component abbreviation Component name 5V interlock switch 24V interlock switch Power switch Cassette media size switch Front door switch Right door switch Test print switch...

  • Page 60: Sensors

    Sensors Table 1-4 Sensors Component abbreviation Component name Yellow drum home position sensor Magenta drum home position sensor Cyan drum home position sensor Black drum home position sensor Fuser delivery sensor Fuser pressure release sensor MP-tray-media-presence sensor Primary-transfer-roller disengagement sensor SR10 New ITB sensor SR11...

  • Page 61: Motors

    Motors The product has 13 motors. The motors drive the components in the paper-feed and image-formation systems. Table 1-5 Motors Abbreviation Name Purpose Failure detection ITB motor Drives the ITB and residual toner feed screw Fuser motor Drives the fuser sleeve, pressure roller, fuser pressure roller, and primary transfer roller disengagement...

  • Page 62: Fans

    Table 1-5 Motors (continued) Abbreviation Name Purpose Failure detection Pickup motor Drives the cassette pickup roller, MP tray pickup roller, feed roller, and cassette separation roller IPTU feed motor Drive the IPTU feed rollers and IPTU delivery roller The DC controller determines if a motor has failed and notifies the formatter when it encounters the following conditions: The DC controller detects a failure by monitoring a motor: Startup failure: the motor does not reach a specified speed within a specified time from when the...

  • Page 63

    Table 1-6 Fans (continued) Abbreviation Name Cooling area Type Speed Exhaust fan 2 Around the delivery Exhaust Full/half assembly Exhaust fan 1 Around the cartridge Exhaust Full/half Sub power supply fan Around the sub power Intake Full supply IPTU fan 1 Around the IPTU media Intake Full...

  • Page 64: High-voltage Power Supply

    High-voltage power supply The DC controller controls the high-voltage power supply to generate biases. The high-voltage power supply delivers the high-voltage biases to the following components used to transfer toner during the image-formation process: Primary-charging roller (in the cartridge) ● Developing roller (in the cartridge) ●...

  • Page 65

    Table 1-7 High-voltage power supply circuits (continued) Circuit Description Primary-transfer-bias generation The primary transfer bias transfers the toner from each photosensitive drum onto the ITB. The primary transfer bias circuit in the high-voltage power supply generates the biases for each color. Secondary-transfer-bias generation The secondary transfer bias transfers the toner image from the ITB onto the paper.

  • Page 66: Low-voltage Power Supply

    Low-voltage power supply The low-voltage power-supply circuit converts the AC power from the wall receptacle into the DC voltage that the product components use. The product has two low-voltage power-supplies for 110 Volt or 220 Volt input. Figure 1-6 Low-voltage power-supply circuit AC input DC controller Fuse...

  • Page 67: Voltage Detection

    Table 1-8 Converted DC voltages Main DC voltage Sub-voltage Behavior +24 V +24 VA Constantly supplied +24 VB Interrupted when the front door or right door open +5 V +5 VB Constantly supplied +5 VC Interrupted when the front door or right door open +3.3 V 3.3 V...

  • Page 68: Fuser Control

    Low-voltage power supply failure The DC controller determines a low-voltage power supply failure and notifies the formatter when the low-voltage power supply does not supply +24 V. Fuser control The fuser heater-control circuit and the fuser heater safety circuit control the fuser temperature according to commands from the DC controller.

  • Page 69: Fuser Temperature Control

    Fuser temperature control The fuser temperature control maintains the target surface temperature of the fuser sleeve. Figure 1-8 Fuser temperature-control circuit Fuser Low-voltage power supply Fuse /ZEROX Zerocross circuit FSRD1 Fuser sleeve unit Fuser heater /RLD Relay control circuit Relay control circuit Current...

  • Page 70

    Current detection circuit ◦ Thermoswitch ◦ DC controller: The DC controller monitors the detected temperature of the main thermistor and ● sub thermistors. The DC controller deactivates the FIXING HEATER CONTROL signal and releases the relay to interrupt power supply to the fuser heater under the following conditions: TH1: 230°...

  • Page 71: Failure Detection

    Failure detection The DC controller determines a fuser unit failure, deactivates the FIXING HEATER CONTROL signal, releases the relay to interrupt power supply to the fuser heater, and notifies the formatter of a failure status when it encounters any of following conditions: Abnormally high temperatures: Temperatures are too high for any of the following ●...

  • Page 72: Fuser Unit Life Detection

    This product detects if the correct fuser for the product is installed. The fuser from a different product (for example, the HP Color LaserJet CP 3525 Series printer) can be installed in this product, but it will not correctly function.

  • Page 73: Laser/scanner System

    Laser/scanner system The laser/scanner system forms the latent electrostatic image on the photosensitive drums according to the VIDEO signals sent from the formatter. The product has two laser/scanners: one for yellow and magenta and the other for cyan and black. The main components of the laser/scanner system are the laser unit and the scanner motor unit, which are controlled by the signals sent from the DC controller.

  • Page 74: Laser/scanner Failure

    Laser/scanner failure The DC controller determines that a laser/scanner has failed when any of the following conditions occurs: Laser failure: The detected laser intensity does not match a specified value when the product ● initializes. Scanner motor startup failure: The scanner motor does not reach a specified rotation within ●...

  • Page 75

    Figure 1-10 Protective-glass cleaners (PGCs) Laser/scanner system ENWW...

  • Page 76: Image-formation System

    Image-formation system The image-formation system creates the printed image on the paper. The system consists of the following components: Print cartridges ● ● Secondary transfer roller ● Fuser ● Laser /scanner units ● The DC controller controls the laser scanner unit and each of the high-voltage power supplies to form the toner image on the photosensitive drum surface, according to the VIDEO signals.

  • Page 77

    Figure 1-12 Image-formation drive system Fuser motor Primary charging roller Primary Developing charging roller roller Primary Developing charging roller roller Primary Developing charging roller roller Developing roller ITB motor M drum motor Y drum motor C drum motor Bk drum motor Image-formation system ENWW...

  • Page 78: Image-formation Process

    Image-formation process The image-formation system consists of ten steps divided into six functional blocks. Figure 1-13 Image-formation process High-voltage power supply T Fusing unit Secondary transfer roller Laser scanner unit Laser scanner unit Cartridge High-voltage power supply D Functional block Steps Description Latent image formation...

  • Page 79: Step 1: Pre-exposure

    Functional block Steps Description ITB cleaning 9. ITB cleaning Residual toner is removed from the ITB. Drum cleaning 10. Drum cleaning Residual toner is removed from the photosensitive drums. Step 1: Pre-exposure Light from the pre-exposure LED strikes the surface of the photosensitive drum to remove any residual electrical charges from the drum surface.

  • Page 80: Step 3: Laser-beam Exposure

    Step 3: Laser-beam exposure The laser beam strikes the surface of the photosensitive drum in the areas where the image will form. The negative charge neutralizes in those areas, which are then ready to accept toner. Figure 1-16 Laser-beam exposure Laser beam Step 4: Development Toner acquires a negative charge as the developing cylinder contacts the developing blade.

  • Page 81: Step 5: Primary Transfer

    Step 5: Primary transfer The positively charged primary-transfer rollers contact the ITB, giving the ITB a positive charge. The ITB attracts the negatively charged toner from the surface of each photosensitive drum, and the complete toner image transfers onto the ITB. Figure 1-18 Primary transfer Primary transfer bias...

  • Page 82: Step 7: Separation

    Step 7: Separation The stiffness of the paper causes it to separate from the ITB as the ITB bends. The static-charge eliminator removes excess charge from the paper to make sure that the toner fuses correctly. Figure 1-20 Separation Secondary transfer opposed roller Paper Static charge...

  • Page 83: Print Cartridge

    Step 9: ITB cleaning 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 box. Figure 1-22 ITB cleaning Residual toner feed screw Cleaning blade Step 10: Drum cleaning The cleaning blade scrapes the residual toner off the surface of the photosensitive drum, and toner is deposited in the toner collection box in the cartridge.

  • Page 84

    The DC controller rotates the drum motor to drive the photosensitive drum, developing roller, and the primary-charging roller. Figure 1-24 Print-cartridge system DC controller Developing SR11: disengagement Developing disengagement sensor motor Developing unit SR1/SR2/SR3/SR4: Drum home position sensor M3/M4/M5/M6: Drum motor Primary charging roller Developing roller Memory...

  • Page 85: Developing-roller Engagement And Disengagement

    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 memory tag. The DC controller notifies the formatter when a cartridge is missing or installed in the incorrect slot.

  • Page 86: Intermediate Transfer Belt (itb) Unit

    The developing-roller engagement and disengagement control operates as follows: When the product is turned on and when each print job is completed, all four of the developing units are disengaged from the photosensitive drums. The drive of the developing disengagement motor rotates the developing disengagement cam. ●...

  • Page 87: Primary-transfer-roller Engagement And Disengagement

    Primary-transfer-roller engagement and disengagement The sequence of the primary-transfer-roller engagement and disengagement control is as follows: The fuser motor turns on the primary-transfer disengagement solenoid and rotates the primary- transfer-roller disengagement cam. As the cam rotates, the Y/M/C primary-transfer-roller slide plate or the Bk primary-transfer-roller slide plate moves to the right or left, which causes the primary-transfer roller to move up or down.

  • Page 88

    The DC controller determines the absences of an ITB unit and notifies the formatter when it does not detect a specified signal from the new primary transfer-roller disengagement sensor. Figure 1-27 Three states of primary-transfer-roller engagement and disengagement DC controller Fuser motor <All colors are disengaged>...

  • Page 89: Itb Cleaning

    ITB cleaning The cleaning blade in the ITB cleaner scrapes the residual toner off the ITB surface. The residual toner feed screw deposits the residual toner to the residual toner feed unit. The ITB motor and the residual toner feed motor drive the screw. The DC control detects whether the toner collection box is full, using the residual-toner full sensor, and then notifies the formatter.

  • Page 90: Color-misregistration Control

    Color-misregistration control Internal variations in the laser/scanners can cause the toner images to become misaligned. The color- misregistration control corrects the following problems: 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 RD sensor.

  • Page 91: Image-stabilization Control

    Image-stabilization control NOTE: The product contains a thermal sensor, located within the TCU level detection sensor, which monitors the temperature in the cartridge area and uses this information to make adjustments during CPR control. Environmental changes or deterioration of the photosensitive drums and toner can cause variations in the image density.

  • Page 92: Pickup, Feed, And Delivery System

    Pickup, feed, and delivery system The pickup, feed, and delivery system uses a series of rollers to move the paper through the product. Figure 1-30 Paper path Simplex media path Duplex media path Duplex reverse roller Pressure roller Fixing sleeve Secondary transfer roller MP tray pickup roller Cassette feed roller...

  • Page 93

    Figure 1-31 Switches and sensors for the pickup, feed, and delivery system SR26 SR27 SR14 SR15 SR22 SR21 SR20 SR25 SR23 SR24 Abbreviation Component Fuser delivery sensor MP tray media presence sensor SR14 Loop sensor 1 SR15 Loop sensor 2 SR20 Top of page (TOP) sensor SR21...

  • Page 94

    Figure 1-32 Motors and solenoids for the pickup, feed, and delivery system Duplex flapper Pickup arm Lifter Abbreviation Component ITB motor Fuser motor Lifter motor Duplex reverse motor Pickup motor IPTU feed motor Duplex re-pickup clutch Duplex reverse solenoid Multipurpose tray pickup solenoid Cassette pickup solenoid Duplex re-pick clutch Chapter 1 Theory of operation...

  • Page 95

    The pickup, feed, and delivery system is divided into the following three blocks: Pickup-and-feed block: From each pickup source to the fuser inlet ● Fuser-and-delivery block: From the fuser to the delivery destination ● Duplex block: From the duplex reverse unit to duplex re-pickup unit (for duplex models only) ●...

  • Page 96: Cassette Pickup

    Pickup-and-feed unit The pickup-and-feed unit picks an individual sheet of paper from the multipurpose tray or the cassettes, carries it through the secondary-transfer unit, and feeds it into the fuser. Figure 1-34 Pickup-and-feed unit Simplex media path Duplex media path Pickup-and-feed block Cassette pickup The sequence of steps for the cassette-tray pickup operation is the following:...

  • Page 97: Cassette-presence Detection

    As the pickup arm lowers, the cassette pickup roller touches the surface of the paper stack. One sheet of paper feeds into the product. Figure 1-35 Cassette-pickup mechanism DC controller Cassette pickup cam Pickup motor Cassette feed roller Cassette feed roller Cassette pickup roller Pickup arm Cassette pickup roller...

  • Page 98: Cassette Lift Operation And Cassette Paper-presence Detection

    Paper size Cassette media size switch Top switch Center switch Bottom switch Legal Cassette absence Cassette lift operation and cassette paper-presence detection The product keeps the paper stack surface at the correct pickup position. The cassette lift-up operation is performed under the following conditions: The product is turned on ●...

  • Page 99: Multipurpose Tray Pickup

    Cassette multiple-feed prevention In the cassette, a separation roller prevents multiple sheets of paper from entering the paper path. The cassette pickup roller drives the separation roller through a sheet of paper. The rotation of the cassette feed roller through the sheet drives the cassette separation roller. Because it is equipped with a torque limiter, only one sheet is fed into the product.

  • Page 100: Paper Feed

    As the lifting plate rises, the paper is picked up. The multipurpose tray separation pad removes any multiple-fed sheets, and one sheet is fed into the product. The MP-tray media-presence sensor (SR8) detects whether paper is present in the MP tray. Figure 1-38 Multipurpose tray pickup mechanism DC controller...

  • Page 101

    The ITB motor rotates the ITB. The toner image on the ITB is transferred onto the paper, and the paper is fed to the fuser. 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.

  • Page 102: Skew-feed Prevention

    Skew-feed prevention The product can straighten the paper without slowing the feed operation. The leading edge of paper strikes the registration shutter, and the leading edge is aligned with the shutter. As the feed rollers keep pushing the paper, the paper warps. When the force is great enough, the registration shutter opens, and the paper passes through and straightens Figure 1-40...

  • Page 103: Duplex Printing

    controller identifies the type of paper (for example, plain paper, light paper, heavy paper, glossy paper, glossy film, or overhead transparency) and switches to the correct print mode. The DC controller determines a media mismatch error and notifies the formatter under the following condition: Simplex printing The specified print mode is overhead transparency (OHT), but the media sensor detects another ●...

  • Page 104: Fusing And Delivery Unit, Loop Control

    Fusing and delivery unit The fusing and delivery unit fuses the toner onto the paper and delivers the printed page into the output bin. The following controls ensure optimum print quality: The face-down tray media full sensor on the output bin detects whether the tray is full of printed pages. The DC controller notifies the formatter when the sensor is on for a specified time.

  • Page 105

    and loop sensor 2 is for heavy media. The DC controller slows the fuser motor when the sensor is off and speeds up the sensor when the sensor is on. Figure 1-42 Loop-control mechanism Pressure roller SR15: Loop sensor 2 For heavy media SR14: Loop sensor 1 For light media...

  • Page 106: Pressure-roller Pressurization Control

    Pressure-roller pressurization control To prevent excessive wear on the pressure roller and help with jam-clearing procedures, the pressure roller pressurizes only during printing and standby. The DC controller reverses the fuser motor. The fuser motor rotates the fuser pressure-release cam. Figure 1-43 Pressure-roller pressurization control DC controller...

  • Page 107: Duplexing Unit, Duplexing Reverse And Feed Control

    Duplexing unit The duplexing unit reverses the paper and feeds it through the paper path to print the second side. Figure 1-44 Duplexing unit Simplex media path Duplex block Duplex media path Duplexing reverse and feed control The duplex reverse control reverses the paper after the first side is printed and feeds it to the duplex re- pickup position to print the second side of the page.

  • Page 108: Duplex Print Operation

    The duplex reverse motor and the duplex feed clutch stop, and the paper feed operation pauses. After a specified period of time, the duplex reverse motor rotates, and the duplex feed clutch is turned on. The paper is then picked up again. Figure 1-45 Duplex reverse and feed control Duplex reverse unit...

  • Page 109

    The formatter specifies the duplex-media-feed mode for each two-sided print job. Duplex printable media size (A4, Letter, B5, Legal and Executive) and designated print mode (Auto, Normal, Heavy media 1, Heavy media 2 (120 g/m2 or lighter), Glossy media 1, Glossy media 2, Glossy media 3, Glossy film, Designated media 1, and Designated media 2) must be specified.

  • Page 110: Jam Detection

    Jam detection The product uses the following sensors to detect the paper as it moves through the paper path and to report to the DC controller if the paper has jammed. Fuser delivery sensor (SR5) ● Top of page (TOP) sensor (SR20) ●...

  • Page 111

    Table 1-14 Jams that the product detects Description Pickup delay jam The TOP sensor does not detect the leading edge of the paper within a specified time (including two retries) after the pickup operation from the cassette, multipurpose tray, or optional paper feeder starts. Pickup stationary jam The TOP sensor does not detect the trailing edge of the paper within a specified time from when it detects the leading edge.

  • Page 112

    Table 1-14 Jams that the product detects (continued) Description IPTU delivery stationary The IPTU media feed sensor does not detect the trailing edge of paper jam 1 within a specified period after it detects the leading edge. IPTU delivery stationary The IPTU media feed sensor detects a paper absence yet it does not detect jam 2 the trailing edge of paper after it detects the leading edge.

  • Page 113: Optional Paper Feeders

    Optional paper feeders Three types of optional paper feeders are available for the product: 1 x 500 sheet paper feeder ● 1 x 500 sheet paper feeder and cabinet ● 3 x 500 paper feeder and stand ● The operational sequence of the paper feeders is controlled by the paper feeder controller. Figure 1-47 1 x 500 optional paper feeder PD feed roller...

  • Page 114

    Figure 1-48 3 x 500-sheet optional paper feeder PD feed roller PD pickup roller PD separation roller Figure 1-49 Signals for the paper feeder Paper deck Motor +3.3V Solenoid +24V Paper deck DC controller controller Photointerrupter Switch The input trays contain several motors, solenoids, sensors, and switches, as described in the following table.

  • Page 115: Motor Control

    Table 1-15 Electrical components for the paper feeder Component Abbreviation Component name type Motors PD lifter motor 1 PD pickup motor PD lifter motor 2 (3 x 500-sheet paper feeder only) PD lifter motor 3 (3 x 500-sheet paper feeder only) Solenoids PD pickup solenoid 1 PD pickup solenoid 2 (3 x 500-sheet paper feeder only)

  • Page 116: Paper-feeder Pickup And Feed Operation

    Component Drives Failure detection PD lifter motor 2 (3 x 500-sheet paper Lifter of the middle cassette feeder only) PD lifter motor 3 (3 x 500-sheet paper Lifter of the lower cassette feeder only) PD pickup motor PD pickup roller, PD feed roller, and PD separation roller Paper-feeder pickup and feed operation The paper feeder picks up one sheet from the paper-feeder cassette and feeds it to the product.

  • Page 117

    Table 1-16 Pickup feed components (1 x 500-sheet paper feeder) (continued) Component PD pickup solenoid 1 Tray 3 paper surface sensor 1 Tray 3 paper surface sensor 2 Tray 3 paper presence sensor Tray 3 paper present sensor Tray 3 paper size switches Pickup arm SR10 SR11...

  • Page 118: Paper-size Detection And Cassette-presence Detection

    PD pickup solenoid 3 Tray 3 paper surface sensor 1 Tray 3 paper surface sensor 2 Tray 3 paper presence sensor Tray 3 paper presence sensor Tray 4 paper surface sensor 1 (3 x 500-sheet paper feeder only) Tray 4 paper surface sensor 2 (3 x 500-sheet paper feeder only) Tray 4 feed sensor (3 x 500-sheet paper feeder only) Tray 4 media-stack-surface sensor (3 x 500-sheet paper feeder only) Tray 5 paper surface sensor 1 (3 x 500-sheet paper feeder only)

  • Page 119: Paper-feeder Cassette Lift Operation

    Paper-feeder cassette lift operation The paper feeder keeps the paper stack surface at the correct pickup position. The cassette lift operation occurs under the following conditions: The product is turned on. ● The cassette is inserted. ● The paper stack surface of the cassette lowers. ●...

  • Page 120: Paper Feeder Jam Detection

    Paper feeder jam detection The 1 x 500-sheet paper feeder uses the Tray 3 paper presence sensor (SR4) to detect the presence of paper and to check whether paper has jammed. Figure 1-52 Jam detection (1 x 500-sheet paper feeder) The 1 x 500-sheet paper feeder detects the following jams: 1 x 500-sheet PD pickup delay jam: Tray 3 feed sensor does not detect the leading edge of paper ●...

  • Page 121

    Figure 1-53 Jam detection (3 x 500-sheet paper feeder) SR10 The 3 x 500-sheet paper feeder detects the following jams: 3 x 500-sheet PD pickup delay jam: One of the tray feed sensors does not detect the leading edge ● of paper within a specified time (including two retries) after the pickup operation starts.

  • Page 122: Scanner Subsystem

    Document feeder/scanner assembly The document feeder/scanner assembly consists of a document feeder and flatbed scanner. The document feeder can feed 50 pages of letter or A4 size paper at speeds up to 57 images per minute in simplex and 24 images per minute in duplex. The document feeder features legal size detection and customer replaceable feed and separation rollers and pads.

  • Page 123: Document Feeder/scanner Motor And Fan Control

    The relay PCA in the document feeder provides connections only to the various components such as fans, motors, and sensors. The control and monitoring of these components takes place on the SCB. Document feeder/scanner motor and fan control Component Purpose Type Rotation Timing...

  • Page 124: Legal Detection Sensor Sequence

    Legal detection sensor sequence The legal detection status displays in the following circumstances: Document feeder legal detection: ● When the document feeder legal sensor is turned on. ◦ Flatbed legal detection: ● When the flatbed legal sensor is turned on while the flatbed angle sensor is opened. ◦...

  • Page 125: Optical Assembly Operation

    Optical assembly operation Figure 1-55 Optical assembly operation Document Reflector Scanner lamp Glass Inverter circuit Scanner controller Lens Second mirror First mirror Third mirror Carriage home position sensor The optical assembly contains the lamp, mirrors, lens, and charge-coupled device (CCD). As the optical assembly moves across the original, the lens focuses the reflected image onto the CCD.

  • Page 126: Clearing A Jam

    Document feeder/scanner paper path and sensors Figure 1-57 Document feeder/scanner paper path and sensors ADF paper present FB cover angle sensor FB cover sensor Delivery Tray ADF sensor FB Y (length) sensor Carriage Home Position sensor Jam detection sequence A jam error occurs in the document feeder. The feed and read motors stop immediately.

  • Page 127: Document Feeder Pick Mechanism

    Sensor Description Registration sensor A jam is detected when the registration sensor does not detected the leading edge of paper when turning paper over during the duplexing process. A jam is detected when the registration sensor does not detected the trailing edge of paper. Read sensor A jam is detected when the read sensor does not detected the leading edge of paper.

  • Page 128: Bin Stapling Mailbox

    3-bin stapling mailbox The 3-bin stapling mailbox installs on the delivery assembly and delivers paper to the output bin. The 3- bin stapling mailbox has two modes: Stacker mode ● Mailbox/job separator mode ● Stapling is available for both modes. Figure 1-58 3-bin stapling mailbox Stamp...

  • Page 129

    Table 1-17 Electrical components for the 3-bin stapling mailbox Component Abbreviation Component name type Motors Stapler motor Jogger motor Paddle motor Stapler/Stacker feed motor Stapler/Stacker lifter motor Solenoids Stamp solenoid Inlet solenoid Output bin solenoid Sensors Output bin 3 delivery sensor Stapler/Stacker media feed sensor 1 Output bin 3 media full sensor Alignment roller sensor...

  • Page 130

    Motor control Jogger motor Paddle motor Stapler/Stacker feed motor Stapler/Stacker lifter motor Stapler motor The 3-bin stapling mailbox has five motors for paper feed, paper delivery, and staple operation. Component Drives Failure detection Stapler motor Stapler Yes (type 2) Jogger motor Jogger guide Yes (type 2) Paddle motor...

  • Page 131

    Failure detection The controller detects a motor failure by monitoring a part related to the motor. If the controller determines a motor failure or motor-related part failure, it notifies the formatter when it encounters the following conditions: Stapler motor: The stapler sensor is not sensed for a specified period of time after the stapler motor ●...

  • Page 132: Delivery Operation

    Delivery operation The 3-bin stapling mailbox has two modes. Stacker mode: The printed page is delivered to output bin 3 first and then delivered to the ● subsequent output bins. Mailbox/job separator mode: The printed page is delivered to the specified output bin for each ●...

  • Page 133: Staple Operation

    Table 1-18 Delivery components (3-bin stapling mailbox) (continued) Component Stapler/Stacker media feed sensor 1 Output bin 3 media full sensor Alignment roller sensor Stapler/Stacker media feed sensor 2 Jogger sensor Output bin 3 upper delivery roller sensor PS2501 Output bin 1 media presence sensor PS2502 Output bin 2 media full sensor PS2503...

  • Page 134

    The printed page from the product is fed to the staple tray. Figure 1-61 3-bin stapling mailbox stapler operation (1 of 4) Stapler/Stacker feed motor Output bin 3 upper delivery rolle r Output bin 3 delivery roller sensor Stapler/Stacker feed roller 2 Paddle motor Staple tray Output bin 3 lower delivery rolle r...

  • Page 135

    The printed page on the staple tray is aligned. For horizontal alignment, the jogger motor rotates and moves the jogger guide. For vertical alignment, the paddle motor is reversed and the alignment roller pushes the page. Figure 1-62 3-bin stapling mailbox stapler operation (2 of 4) Jogger guide Paddle motor Jogger sensor...

  • Page 136

    After all of the pages are aligned, the pages are stapled together while being held with the stamp. Figure 1-63 3-bin stapling mailbox stapler operation (3 of 4) Stamp solenoid Stamp Staple tray The paddle motor rotates, and the output bin 3 upper delivery roller touches the stapled pages. The stapler/stacker feed motor rotates to rotate the output bin 3 upper delivery roller and the output bin 3 lower delivery roller.

  • Page 137

    The stapler/stacker feed motor starts rotating while the jogger motor is reversed and the jogger guide moves to its home position. Figure 1-64 3-bin stapling mailbox stapler operation (4 of 4) Stapler/Stacker feed motor Jogger guide Paddle motor Jogger motor Output bin 3 media full sensor Output bin 3 Stapler/Stacker lifter motor...

  • Page 138: Stapler

    Stapler The stapler consists of the staple cartridge and the stapler assembly. The staple cartridge holds up to 5,000 staples. The staple presence sensor detects the presence of staple. The staple ready sensor detects whether the stapler is in the correct position to staple. The staple assembly is equipped with the stapler motor.

  • Page 139: Output Bin 3 Lift Operation

    Output bin 3 lift operation Figure 1-66 3-bin stapling mailbox sensors for output bin 3 lift operation Output bin 3 Output bin 3 media full sensor PS2601 Output bin 3 higher limit sensor PS2602 Output bin 3 lower limit sensor Stapler/Stacker lifter motor The operational sequence of the output bin 3 lift operation is as follows: The stapler/stacker lifter motor rotates if both the output bin 3 higher limit sensor and the output...

  • Page 140: Stacker Mode

    The stapler/stacker controller determines a stapler/stacker lifter motor failure. The controller notifies the formatter through the DC controller when it encounters the following conditions after the stapler/stacker lifter motor starts rotating: Output bin 3 does not reach the output bin 3 higher limit sensor within a specified period of time. ●...

  • Page 141: Mailbox/job Separator Mode

    The stapler/stacker controller determines a if the 3-bin stapling mailbox is full and notifies the formatter through the DC controller when it encounters the following condition: The output bin 1 media full is detected. ● The staple operation is designated when the output bin 3 is full of paper. ●...

  • Page 142

    Jam Detection The 3-bin stapling mailbox uses the following sensors to detect the presence of paper and to check whether paper is being fed correctly or has jammed: Output bin 3 delivery sensor (SR1) ● Stapler/stacker media feed sensor 1 (SR2) ●...

  • Page 143: Automatic Delivery

    Stapler/Stacker feed stationary jam 3: The output bin 3 delivery sensor does not detect the trailing ● edge of paper within a specified period of time from when the stapler/stacker feed motor starts rotating after a staple operation. Stapler/Stacker residual paper jam: Any one of the following sensors detects a presence of paper ●...

  • Page 144

    Chapter 1 Theory of operation ENWW...

  • Page 145: Removal And Replacement

    Removal and replacement Introduction ● Removal and replacement strategy ● Electrostatic discharge ● Required tools ● Before performing service ● After performing service ● Post-service test ● Parts removal order ● Customer self repair (CSR) components ● External panels, covers, and doors ●...

  • Page 146: Removal And Replacement Strategy

    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.

  • Page 147: Electrostatic Discharge, Required Tools

    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.

  • Page 148: Before Performing Service, After Performing Service

    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 ●...

  • Page 149: Post-service Test

    Post-service test Perform the following test to verify that the repair or replacement was successful. Print-quality test Verify that you have completed the necessary reassembly steps. Make sure that the tray contains clean, unmarked paper. Attach the power cord and interface cable or interface cables, and then turn on the product. Verify that the expected startup sounds occur.

  • Page 150: Parts Removal Order

    Parts removal order Figure 2-2 Parts removal order (1 of 2) Roller cover Standard output bin Output bin bezel S-CVR-REAR (scanner rear cover) ASY-CBR-F-SP (ADF front cover) ASY-CBR-F-R-SP (ADF rear cover) S-CVR-LEFT (scanner left cover) Control panel S-CVR-REAR Scanner Fan cover Standard output bin Output bin bezel Right-front cover...

  • Page 151

    Figure 2-3 Parts removal order (2 of 2) Scanner IPTU Residual-toner Delivery fan feed motor IPTU Scanner IPTU Delivery Fan Scanner IPTU Delivery Fan Delivery Assembly Scanner assy IPTU Delivery Fan Scanner assy Image scanner power supply unit (PSU) Scanner Image scanner (PSU) ICB Scanner assy Image scanner (PSU) LVPS...

  • Page 152: Control Panel

    Customer self repair (CSR) components Control panel Lift the control panel. Figure 2-4 Remove the control panel (1 of 3) Remove one screw. Figure 2-5 Remove the control panel (2 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 153

    Disconnect one connector, and then move the control panel to the right to remove. Figure 2-6 Remove the control panel (3 of 3) Customer self repair (CSR) components ENWW...

  • Page 154

    When reinstalling the control panel, make sure the bracket fits correctly on the product. Figure 2-7 Incorrect installation of the control panel Figure 2-8 Correct installation of the control panel Chapter 2 Removal and replacement ENWW...

  • Page 155: Print Cartridges

    Print cartridges CAUTION: If toner gets on your clothing, wipe it off with a dry cloth and wash clothing in cold water. Hot water sets toner into fabric. Open the front door. Make sure that the door is completely open. Figure 2-9 Remove the print cartridge (1 of 2) Grasp the print-cartridge handle and pull out to remove.

  • Page 156: Toner-collection Unit

    Toner-collection unit NOTE: The toner-collection unit is designed for a single use. Do not try to empty the toner-collection unit and reuse it. Doing so could cause toner to spill inside the product and result in reduced print quality. For recycling information, see the product user guide. Open the front door.

  • Page 157

    To prevent toner spills, place the blue cap (callout 1) over the blue opening at the top of the unit (callout 2). Figure 2-13 Remove the toner-collection unit (3 of 4) Figure 2-14 Remove the toner-collection unit (4 of 4) Customer self repair (CSR) components ENWW...

  • Page 158: Formatter Pca

    Formatter PCA CAUTION: ESD sensitive component. Turn the product off and disconnect the power and interface cable or interface cables. Unscrew the formatter thumb screws, and then firmly pull the formatter from the product. Place the formatter on a clean, flat, grounded surface. Figure 2-15 Remove the formatter Remove the hard drive and fax card from the existing formatter and reinstall on the new formatter.

  • Page 159: Fax Card

    Fax card Before proceeding, remove the following components: Formatter PCA. See Formatter PCA on page 106. ● Remove the fax card CAUTION: ESD sensitive component. Lift the inside edge of the fax card and then remove. ▲ Figure 2-16 Remove the fax card Reinstallation tip Make sure that the fax card is installed correctly.

  • Page 160: Hard Drive

    Hard drive Before proceeding, remove the following components: Formatter PCA. See Formatter PCA on page 106. ● Remove the hard drive CAUTION: ESD sensitive component. Disconnect three connectors. Figure 2-17 Remove the hard drive (1 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 161: Upgrade The Firmware

    Upgrade the firmware to the new hard drive. Upgrade the firmware Go to www.hp.com/go/cljcm4540mfp_firmware and follow the onscreen steps to download the most recent firmware upgrade files for your product. Copy the firmware update file to a portable USB flash memory storage device (thumb drive).

  • Page 162

    Reinstall the formatter with the new hard drive and reconnect the power cord and network connection. Turn the product on. Press and hold the Stop button when all of the LEDs illuminate solid. Press the button to highlight the Administrator menu, and then press the button.

  • Page 163: Tray

    Tray NOTE: Use this procedure to remove Tray 2 and the optional Trays 3, 4, and 5. Pull the tray straight out of the product until it stops. Figure 2-20 Remove the tray (1 of 2) Push the tray in slightly, carefully lift up to release it, and then remove the tray. Figure 2-21 Remove the tray (2 of 2) Customer self repair (CSR) components...

  • Page 164: Fuser

    Fuser CAUTION: The fuser might be hot. Allow enough time after turning off the product power for the fuser to cool. NOTE: The product detects a new fuser using a fusible link that blows after 100 pages have been printed. If a new fuser is installed for troubleshooting purposes, be sure to remove it before printing 100 pages.

  • Page 165: Feed And Separation Rollers (trays 2-5)

    Feed and separation rollers (Trays 2-5) CAUTION: Do not touch the spongy roller surface unless you are replacing the roller. Skin oils on the roller can cause paper pickup problems. Locate the feed and separation rollers for the tray. TIP: You do not have to separate the product from the feeder to remove these rollers.

  • Page 166: Pickup Roller (tray 1)

    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. Open Tray 1. Figure 2-25 Remove the pickup roller (Tray 1) (1 of 5) Push the top edge of the cover to release the tabs.

  • Page 167

    Open the right-door assembly, and then remove the cover. Figure 2-27 Remove the pickup roller (Tray 1) (3 of 5) Release the two blue tabs. Figure 2-28 Remove the pickup roller (Tray 1) (4 of 5) Customer self repair (CSR) components ENWW...

  • Page 168

    Rotate the roller body away from the product to remove it. Figure 2-29 Remove the pickup roller (Tray 1) (5 of 5) Chapter 2 Removal and replacement ENWW...

  • Page 169: Reinstalling The Pickup Roller (tray 1)

    Reinstalling the pickup roller (Tray 1) When reinstalling the pickup roller, make sure the roller cover is installed correctly. Incorrect ▲ installation can cause paper to jam. Figure 2-30 Incorrect position of cover Figure 2-31 Correct position of cover Customer self repair (CSR) components ENWW...

  • Page 170: Secondary Transfer Roller

    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. Open the right-door assembly. Figure 2-32 Remove the transfer roller (1 of 3) Use the blue lever to lower the secondary transfer assembly.

  • Page 171: Reinstall The Transfer Roller

    Grasp the roller shaft collars, and lift the transfer roller off of the product. Figure 2-34 Remove the transfer roller (3 of 3) Reinstall the transfer roller When you reinstall the transfer roller, make sure that the pins on the shaft collars align with the holes in the mounting assembly.

  • Page 172: Intermediate Transfer Belt (itb)

    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. Open the right-door assembly. Figure 2-36 Remove the intermediate transfer belt (1 of 4) Use the blue lever to lower the secondary transfer assembly.

  • Page 173

    Grasp the small handles on the ITB and then pull the ITB out of the product until two large handles expand along the right- and left-side of the ITB. Figure 2-38 Remove the intermediate transfer belt (3 of 4) Customer self repair (CSR) components ENWW...

  • Page 174

    Grasp the large handles on the ITB and then pull the ITB straight out of the product to remove it. 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 2-39 Remove the intermediate transfer belt (4 of 4) Reinstallation tip...

  • Page 175: Standard Output Bin

    Standard output bin Lift and pull the output bin to remove. ▲ Figure 2-40 Remove the standard output bin Customer self repair (CSR) components ENWW...

  • Page 176: Output Bin Bezel

    Output bin bezel Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123 ● Remove the output bin bezel Release two latches, and then slide the bezel up to remove. ▲ Figure 2-41 Remove output bin bezel ASY-TRY-F-BASE-SP (document feeder tray extender) Pull the tray extender out, lift, and then remove.

  • Page 177: Asy-cvr-fe-pick-sp (pickup Roller Cover)

    ASY-CVR-FE-PICK-SP (pickup roller cover) Open the jam access cover. Release the cover latch (callout 1). Lower the cover (callout 2) and then pull (callout 3) the cover to remove. Figure 2-43 Remove the ASY-CVR-FE-PICK-SP (pickup roller cover) ASY-ROL-FE-FEED-SP (pickup roller) Open the jam access cover (callout 1).

  • Page 178: Asy-hld-rev-pad-sp (pickup Roller Pad) And Asy-sp-rev-spr (spring)

    ASY-HLD-REV-PAD-SP (pickup roller pad) and ASY-SP-REV-SPR (spring) Open the jam access cover. Release one tab. Figure 2-45 Remove the ASY-CVR-FE-PICK-SP (pickup roller cover) Slide the pad (callout 1) and then lift back edge to remove (callout 2). Remove the spring if necessary.

  • Page 179: Identification And Location

    External panels, covers, and doors Identification and location Figure 2-47 External panels, covers, and doors; identification and location Item Description Item Description ASY-CVR-F-SP (document feeder front cover) (see Right-door assembly (see Right-door assembly ASY-CVR-F-SP (document feeder front cover) on page 145) on page 129)

  • Page 180: S-cvr-rear (scanner Rear Cover)

    S-CVR-REAR (scanner rear cover) Remove one screw. Figure 2-48 Remove S-CVR-REAR (scanner rear cover) (1 of 2) Release one tab, and then remove the scanner cover. Figure 2-49 Remove S-CVR-REAR (scanner rear cover) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 181: Asy-cvr-f-sp (document Feeder Front Cover)

    ASY-CVR-F-SP (document feeder front cover) Lift the jam cover. Figure 2-50 Remove ASY-CVR-F-SP (document feeder front cover) (1 of 4) Remove one screw. Figure 2-51 Remove ASY-CVR-F-SP (document feeder front cover) (2 of 4) External panels, covers, and doors ENWW...

  • Page 182

    Open the document feeder and then remove two screws. Figure 2-52 Remove ASY-CVR-F-SP (document feeder front cover) (3 of 4) Close the document feeder and then remove the document feeder front cover. Figure 2-53 Remove ASY-CVR-F-SP (document feeder front cover) (4 of 4) Chapter 2 Removal and replacement ENWW...

  • Page 183: Asy-cvr-f-r-sp (document Feeder Rear Cover)

    ASY-CVR-F-R-SP (document feeder rear cover) Open the jam cover. Figure 2-54 Remove the ASY-CVR-F-R-SP (document feeder rear cover) (1 of 5) Remove one screw. Figure 2-55 Remove the ASY-CVR-F-R-SP (document feeder rear cover) (2 of 5) External panels, covers, and doors ENWW...

  • Page 184

    Open the document feeder and then remove one screw. Figure 2-56 Remove the ASY-CVR-F-R-SP (document feeder rear cover) (3 of 5) Release one tab (callout 1) and then lift the document feeder rear cover (callout 2). Figure 2-57 Remove the ASY-CVR-F-R-SP (document feeder rear cover) (4 of 5) Chapter 2 Removal and replacement ENWW...

  • Page 185: S-cvr-left (scanner Left Cover)

    Remove the document feeder rear cover. Figure 2-58 Remove the ASY-CVR-F-R-SP (document feeder rear cover) (5 of 5) S-CVR-LEFT (scanner left cover) Remove one screw. Figure 2-59 Remove S-CVR-LEFT (scanner left cover) (1 of 2) External panels, covers, and doors ENWW...

  • Page 186: Fan Cover

    Lift the scanner left cover to remove. Figure 2-60 Remove S-CVR-LEFT (scanner left cover) (2 of 2) Fan cover Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124.

  • Page 187: Remove The Fan Cover

    Remove the fan cover Remove one screw and then remove the fan cover. ▲ Figure 2-61 Remove upper left cover External panels, covers, and doors ENWW...

  • Page 188: Lower-left Cover

    Lower-left cover Remove one screw (callout 1), release two tabs (callout 2), and then remove the lower-left cover ▲ (callout 3). Figure 2-62 Remove the lower-left cover Chapter 2 Removal and replacement ENWW...

  • Page 189: Left Cover, Remove The Left Cover

    Left cover Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 190: Right-front Cover

    Right-front cover Remove the right-front cover NOTE: Be careful. When removing the cover, do not dislodge the power button. If the button is dislodged, see Reinstall the power button on page 139 to reinstall it. Open the right-door and front door assemblies. Release three tabs.

  • Page 191: Reinstall The Power Button

    Reinstall the power button Snap the power button into the holders on the cover. Make sure that the spring is correctly installed. Figure 2-66 Reinstall the power button External panels, covers, and doors ENWW...

  • Page 192: Front-door Assembly

    Front-door assembly Before proceeding, remove the following components: Right-front cover. See Right-front cover on page 138 ● Remove the front-door assembly Open the front-door assembly. Release the right link arm by pushing the two segments together and then releasing. Figure 2-67 Remove the front-door assembly (1 of 5) Chapter 2 Removal and replacement ENWW...

  • Page 193

    Squeeze the tab on the left link arm using needle nose pliers to release it from the front door assembly. NOTE: Hold the link arm firmly when releasing to prevent it from snapping against the front of the product. Figure 2-68 Remove the front-door assembly (2 of 5) Remove two screws (callout 1).

  • Page 194

    Remove two screws. Figure 2-70 Remove the front-door assembly (4 of 5) Remove the front-door assembly. Figure 2-71 Remove the front-door assembly (5 of 5) Chapter 2 Removal and replacement ENWW...

  • Page 195: Right-rear Cover

    Right-rear cover Before proceeding, remove the following components: Document feeder. See Document feeder on page 151. ● Standard output bin. See S-CVR-REAR (scanner rear cover) on page 128. ● Scanner assembly. See Scanner on page 170. ● Intermediate cover and duplexing gear cover. See Intermediate cover and duplexing gear cover ●...

  • Page 196: Rear Cover, Remove The Rear Cover

    Rear cover Before proceeding, remove the following components: S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133. ● Fan cover. See Fan cover on page 134. ● Lower-left cover. See Lower-left cover on page 136. ● Remove the rear cover Remove one screws (callout 1), release one tab (callout 2), and then slide the cover to the right to ▲...

  • Page 197: Right-door Assembly

    Right-door assembly Open the right-door assembly. Figure 2-74 Remove the right-door assembly (1 of 9) Remove three screws. Figure 2-75 Remove the right-door assembly (2 of 9) External panels, covers, and doors ENWW...

  • Page 198

    Remove the hinge assembly. Reinstallation tip When the hinge is reinstalled, make sure that the tab (callout 1) is correctly positioned on the door. Figure 2-76 Remove the right-door assembly (3 of 9) Remove the hinge cover. Figure 2-77 Remove the right-door assembly (4 of 9) Chapter 2 Removal and replacement ENWW...

  • Page 199

    Release one pin, and then release the link arm (callout 1). CAUTION: The link arm is spring loaded. Hold the arm securely (as shown) to prevent the spring from abruptly retracting. Figure 2-78 Remove the right-door assembly (5 of 9) Release one tab, and then remove the cover (callout 1).

  • Page 200

    Disconnect two connectors. Figure 2-80 Remove the right-door assembly (7 of 9) Lift two link arms to release. Figure 2-81 Remove the right-door assembly (8 of 9) Chapter 2 Removal and replacement ENWW...

  • Page 201

    Slide the right-door assembly toward the front of the product and remove. Figure 2-82 Remove the right-door assembly (9 of 9) External panels, covers, and doors ENWW...

  • Page 202: Document Feeder

    Document feeder ASY-LVR-FE-EMP-SP (paper present flag) Open the jam access cover. Release the flag from the hinge. Figure 2-83 Remove the ASY-LVR-FE-EMP-SP (paper present flag) (1 of 2) Pull the flag to release and remove. Figure 2-84 Remove the ASY-LVR-FE-EMP-SP (paper present flag) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 203: Remove The Document Feeder

    Document feeder Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Remove the document feeder Remove one screw (callout 1) and disconnect two connectors (callout 2). Figure 2-85 Remove the document feeder (1 of 3) Remove two screws.

  • Page 204: Reinstall The Document Feeder

    From the rear of the product, lift the document feeder to remove. Figure 2-87 Remove the document feeder (3 of 3) Reinstall the document feeder Make sure the cable retainer is installed inside the cavity. ▲ Figure 2-88 Reinstall the document feeder Chapter 2 Removal and replacement ENWW...

  • Page 205: Asy-cvr-fe-feed-sp (document Feeder Jam-access Cover)

    ASY-CVR-FE-FEED-SP (document feeder jam-access cover) Before proceeding, remove the following components: ASY-CVR-F-SP (document feeder front cover). See ASY-CVR-F-SP (document feeder front cover) ● on page 129. ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131.

  • Page 206

    Lift the cover slightly, and then pull the cover toward the front of the product to remove. Figure 2-90 Remove the ASY-CVR-FE-FEED-SP (document feeder jam-access cover) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 207: Asy-try-sp (tray Assembly)

    ASY-TRY-SP (tray assembly) Before proceeding, remove the following components ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Remove the ASY-TRY-SP (tray assembly) Open the jam-access cover. Disconnect one connector (callout 1) and release the cable from the cable guides (callout 2). Figure 2-91 Remove the ASY-TRY-SP (tray assembly) (1 of 2) Document feeder...

  • Page 208

    Release the pin from the hinge (callout 1) and then remove the tray assembly (callout 2). Figure 2-92 Remove the ASY-TRY-SP (tray assembly) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 209: Asy-frm-re-feed-sp (internal Assembly)

    ASY-FRM-RE-FEED-SP (internal assembly) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-SP (document feeder front cover). See ASY-CVR-F-SP (document feeder front cover) ● on page 129. ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ●...

  • Page 210

    Remove two screws. Figure 2-94 Remove the ASY-FRM-RE-FEED-SP (internal assembly) (2 of 3) Remove five screws, and then remove the assembly. Figure 2-95 Remove the ASY-FRM-RE-FEED-SP (internal assembly) (3 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 211: Asy-pba-relay-sb (document Feeder Pca)

    ASY-PBA-RELAY-SB (document feeder PCA) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 212: Asm-if-sp (document Feeder Cable)

    ASM-IF-SP (document feeder cable) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover) S-CVR-REAR (scanner rear cover) on page 128 ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 213: Remove The Asm-if-sp (document Feeder Cable)

    Remove the ASM-IF-SP (document feeder cable) Remove one screw (callout 1), release the cable guides (callout 2), disconnect two connectors ▲ (callout 3), release one tab (callout 4). Remove the document feeder cable. Figure 2-97 Remove the ASM-IF-SP (document feeder cable) (1 of 2) NOTE: When reinstalling the cable, make sure to correctly wrap the cable in the toroid.

  • Page 214: Asy-hng-l-sp (document Feeder Left Hinge)

    ASY-HNG-L-SP (document feeder left hinge) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 215: Asy-hng-r-sp (document Feeder Right Hinge)

    ASY-HNG-R-SP (document feeder right hinge) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 216: Asy-fan-sp (document Feeder Fan)

    ASY-FAN-SP (document feeder fan) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 217: Asy-mot-fe-sp (motor)

    ASY-MOT-FE-SP (motor) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 218: Asy-mot-re-sp (document Feeder Motor)

    ASY-MOT-RE-SP (document feeder motor) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 219: Asy-dfsens-sp (document Feeder Open Sensor)

    ASY-DFSENS-SP (document feeder open sensor) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder. See Document feeder on page 151.

  • Page 220: Asy-gidrev-spr-sp (document Feeder Jam Access Plate)

    ASY-GIDREV-SPR-SP (document feeder jam access plate) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. Document feeder.

  • Page 221: Asy-base_sb (base Assembly)

    ASY-BASE_SB (base assembly) Before proceeding, remove the following components ASY-CVR-F-SP (document feeder front cover). See ASY-CVR-F-SP (document feeder front cover) ● on page 129. ASY-CVR-F-R-SP (document feeder rear cover). See ASY-CVR-F-R-SP (document feeder rear cover) ● on page 131. ASY-CVR-FE-FEED-SP (document feeder jam-access cover). See ASY-CVR-FE-FEED-SP (document ●...

  • Page 222: Scanner Filter Cover And Scanner Filter

    Scanner Scanner filter cover and scanner filter Remove the scanner-filter cover (callout 1). Figure 2-107 Remove the scanner filter (1 of 2) Remove the filter (callout 1). Figure 2-108 Remove the scanner filter (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 223: Scanner Assembly

    Scanner assembly Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Document feeder. See Document feeder on page 151. ● Remove the scanner Carefully open the scanner.

  • Page 224

    Lower the jam access cover. Figure 2-110 Remove the scanner assembly (2 of 6) Release two scissor hinges (callout 1). Figure 2-111 Remove the scanner assembly (3 of 6) Chapter 2 Removal and replacement ENWW...

  • Page 225

    Disconnect two connectors (callout 1) and release the safety cable (callout 2). Figure 2-112 Remove the scanner assembly (4 of 6) WARNING! The scanner is no longer secured to the product. To prevent the scanner from falling from the product, firmly grasp the scanner when opening. Disconnect one connector (callout 1), and then release the cable from the cable guides (callout 2).

  • Page 226: Scissor Hinge Assemblies

    From the rear of the product, lift the scanner to remove. Figure 2-114 Remove the scanner assembly (6 of 6) Scissor hinge assemblies Open the scanner and then lower the jam access cover. Figure 2-115 Remove the scissor hinge assembly (1 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 227

    Release the top of the two scissor hinges (callout 1). Figure 2-116 Remove the scissor hinge assembly (2 of 3) Release the bottom of the two scissor hinges and remove. Figure 2-117 Remove the scissor hinge assembly (3 of 3) Scanner ENWW...

  • Page 228: S-assy-cp-adapter (cp Adapter Assembly)

    S-ASSY-CP-ADAPTER (CP adapter assembly) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133 ●...

  • Page 229

    Slide the CP adapter assembly to the left to release. Figure 2-119 Remove the S-ASSY-CP-ADAPTER (CP adapter assembly) (2 of 4) Scanner ENWW...

  • Page 230

    Squeeze the retainer to release the cable from the back of the CP adapter assembly. Figure 2-120 Remove the S-ASSY-CP-ADAPTER (CP adapter assembly) (3 of 4) CAUTION: After removing the CP adapter assembly from the scanner, be careful not to damage the ground spring.

  • Page 231: S-pba-scb (scb)

    S-PBA-SCB (SCB) Before proceeding, remove the following components S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Remove the S-PBA-SCB (SCB) CAUTION: ESD-sensitive part. Carefully unlatch the top of the zero insertion force (ZIF) connector to release the flat flexible cable (FFC).

  • Page 232

    Remove five screws (callout 1), disconnect four connectors (callout 2), and then remove the SCB. Figure 2-123 Remove the S-PBA-SCB (SCB) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 233: S-asm-usb (usb Control Panel Cable)

    S-ASM-USB (USB control panel cable) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 234

    Remove five screws (callout 1), and then slide the lift plate (callout 2) and remove. Remove the cable (callout 3). Figure 2-125 Remove the S-ASM-USB (USB control panel cable) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 235: S-hng-lift-r (scanner Release Assembly)

    S-HNG-LIFT-R (scanner release assembly) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 236: S-assy-upper-unit (tub Top)

    S-ASSY-UPPER-UNIT (tub top) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 237: S-pba-tyukei (interconnect Board) And S-sns-ey3a1061–2 (size Sensor)

    S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 238

    Remove the front side shaft. Figure 2-129 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (2 of 4) CAUTION: Grease is applied to the shaft. Avoid removing the grease from the shaft. Keep the grease away from other parts of the product. Disconnect two FFCs and one connector.

  • Page 239

    Remove three screws (callout 1) and the interconnect board and size sensor (callout 2). Figure 2-131 Remove the S-PBA-TYUKEI (interconnect board) and S-SNS-EY3A1061–2 (size sensor) (4 of 4) Scanner ENWW...

  • Page 240: S-assy-inv (inverter)

    S-ASSY-INV (inverter) Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133. ● Document feeder. See Document feeder on page 151.

  • Page 241

    Carefully lift the grounding plate and then remove the inverter. CAUTION: Do not deform the grounding plate. Deforming the grounding plate can cause the optical carriage to malfunction. Figure 2-133 Remove the S-ASSY-INV (inverter) (2 of 2) Scanner ENWW...

  • Page 242: S-fan-mfb-30e-05a-006 (inverter Fan)

    S-FAN-MFB-30E-05A-006 (inverter fan) Before proceeding, remove the following components Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133.

  • Page 243: Assy-crg-unit-ir4068 (optical Assembly)

    ASSY-CRG-UNIT-IR4068 (optical assembly) Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133. ● Document feeder. See Document feeder on page 151.

  • Page 244

    Disconnect one connector (callout 1), release one tab (callout 2), and then slide the inverter cover to the right to remove. Figure 2-136 Remove the ASSY-CRG-UNIT-IR4068 (optical assembly) (2 of 6) Move the carriage to the center of the scanner. Remove one screw (callout 1) and restraint (callout 2).

  • Page 245

    Remove one screw (callout 1), and then remove the stop (callout 2). Figure 2-138 Remove the ASSY-CRG-UNIT-IR4068 (optical assembly) (4 of 6) Compress the spring until it locks (callout 1), and then remove the belt (callout 2) from the pulley. Figure 2-139 Remove the ASSY-CRG-UNIT-IR4068 (optical assembly) (5 of 6) Scanner...

  • Page 246

    Release the belt from the optical assembly and then remove the assembly. Figure 2-140 Remove the ASSY-CRG-UNIT-IR4068 (optical assembly) (6 of 6) CAUTION: Oil is applied to the shaft. Keep oil away from other parts of the product. Chapter 2 Removal and replacement ENWW...

  • Page 247: S-assy-motor-unit (motor Assembly)

    S-ASSY-MOTOR-UNIT (motor assembly) Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133. ● Document feeder. See Document feeder on page 151.

  • Page 248

    Remove three screws (callout 1), release two cables (callout 2) from the cable guides, and then remove the sheet metal box. Figure 2-142 Remove the S-ASSY-MOTOR-UNIT (motor assembly) (2 of 3) Remove five screws, and then remove the motor assembly. Figure 2-143 Remove the S-ASSY-MOTOR-UNIT (motor assembly) (3 of 3) Chapter 2 Removal and replacement...

  • Page 249: S-fan-d06037600g-001 (scanner Fan)

    S-FAN-D06037600G-001 (scanner fan) Control panel. See Control panel on page 100. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● S-CVR-LEFT (scanner left cover). See S-CVR-LEFT (scanner left cover) on page 133. ● Document feeder. See Document feeder on page 151.

  • Page 250

    Remove the foam (callout 1), release the cable from the cable guides (callout 2), and then remove the fan. Figure 2-145 Remove the S-FAN-D06037600G-001 (scanner fan) (2 of 2) CAUTION: When the fan is reinstalled, the air must flow into the product. Check the arrows embossed on the fan frame that indicate air flow direction.

  • Page 251: Internal Assemblies

    Internal 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. IPTU Before proceeding, remove the following components Standard output bin.

  • Page 252

    Lift the cover up on the right side to clear the pin, lift the paper path, rotate the cover on left side to release one tab (callout 1), and then remove the inner cover (callout 2). Figure 2-147 Remove the IPTU (2 of 5) Remove two screws.

  • Page 253

    Remove two screws. Figure 2-149 Remove the IPTU (4 of 5) Disconnect one connector (callout 1) and then lift (callout 2) and slide the IPTU (callout 3) to remove. Figure 2-150 Remove the IPTU (5 of 5) Internal assemblies ENWW...

  • Page 254: Cassette Feed Guide

    Cassette feed guide TIP: If a page is jammed in the product, you might be able to access it by removing this guide. Open the right-door assembly. Figure 2-151 Remove the cassette feed guide (1 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 255

    Remove two screws (callout 1), and then remove the cassette feed guide (callout 2). Figure 2-152 Remove the cassette feed guide (2 of 3) NOTE: When reinstalling the cassette feed guide, make sure to correctly align each screw and pin with the corresponding hole and that the guide fits secure against the chassis. Figure 2-153 Remove the cassette feed guide (3 of 3) Internal assemblies...

  • Page 256: Secondary Transfer Assembly

    Secondary transfer assembly The secondary transfer assembly includes the transfer roller. Open the right-door assembly. Figure 2-154 Remove the secondary transfer assembly (1 of 3) Release one tab and carefully remove the stopper. NOTE: You might have to slightly lift up on the corner of the assembly to release the stopper pin from the hole in the chassis.

  • Page 257: Reinstall The Secondary Transfer Assembly

    Remove the secondary transfer assembly. CAUTION: Do not damage the blue release lever when removing the assembly. Figure 2-156 Remove the secondary transfer assembly (3 of 3) Reinstall the secondary transfer assembly Press and hold the blue release lever when you reinstall the assembly. Figure 2-157 Reinstall the secondary transfer assembly Internal assemblies...

  • Page 258: Separation Pad (tray 1)

    Separation pad (Tray 1) Before proceeding, remove the following components: Pickup roller. See Pickup roller (Tray 1) on page 114. ● Right door assembly. See Right-door assembly on page 145. ● Remove the separation pad (Tray 1) Remove two screws (callout 1) and the cover (callout 2). Figure 2-158 Remove the separation pad (1 of 6) Remove two screws (callout 1) and separate Tray 1 (callout 2) from the door assembly.

  • Page 259

    Release two tabs (callout 1) and slide the locking cap and sub roller toward the edge of the tray. Figure 2-160 Remove the separation pad (3 of 6) Release two tabs (callout 1) and slide the locking cap and sub roller toward the edge of the tray. CAUTION: Do not damage the flag (callout 2).

  • Page 260

    Release one tab (callout 1) and slide the pickup-roller holder toward the edge of the tray. CAUTION: Do not damage the flag (callout 2). Figure 2-162 Remove the separation pad (5 of 6) Release one tab (callout 1) and remove the separation pad. Figure 2-163 Remove the separation pad (6 of 6) Chapter 2 Removal and replacement...

  • Page 261: Registration Density (rd) Sensor Assembly

    Registration density (RD) sensor assembly Before proceeding, remove the following components: Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Secondary transfer assembly. See Secondary transfer assembly on page 204. ● Remove the RD sensor assembly Release one tab (callout 1), and then remove the cover (callout 2).

  • Page 262

    Release one tab, and then remove the wire-harness cover. TIP: Open the front door to make it easier to remove the cover. Figure 2-166 Remove the RD sensor assembly (3 of 7) Disconnect three connectors. Figure 2-167 Remove the RD sensor assembly (4 of 7) Chapter 2 Removal and replacement ENWW...

  • Page 263

    Remove two screws. Figure 2-168 Remove the RD sensor assembly (5 of 7) Slide the shutter toward the back side of the product. Keep the shutter in this position for the following step. Figure 2-169 Remove the RD sensor assembly (6 of 7) Internal assemblies ENWW...

  • Page 264

    Carefully remove the assembly from the product. CAUTION: Do not damage the shutter as it passes through the chassis. Figure 2-170 Remove the RD sensor assembly (7 of 7) Chapter 2 Removal and replacement ENWW...

  • Page 265: Registration Assembly

    Registration assembly Before proceeding, remove the following components: Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Secondary transfer assembly. See Secondary transfer assembly on page 204. ● Internal assemblies ENWW...

  • Page 266: Remove The Registration Assembly

    Remove the registration assembly NOTE: If a replacement registration assembly is installed, you must use the control-panel menus to reset the registration-roller count and input the media sensor value. See Service menu on page 625. Release one tab (callout 1), and then remove the cover (callout 2). Figure 2-171 Remove the registration assembly (1 of 8) NOTE:...

  • Page 267

    Release one tab, and then remove the wire-harness cover. TIP: To make the cover easier to remove, open the front-door assembly to close the RD-sensor shutter. Figure 2-173 Remove the registration assembly (3 of 8) Disconnect two connectors. Figure 2-174 Remove the registration assembly (4 of 8) Internal assemblies ENWW...

  • Page 268

    Remove two screws (callout 1), and then remove the cassette feed guide (callout 2). Figure 2-175 Remove the registration assembly (5 of 8) Remove four screws. Figure 2-176 Remove the registration assembly (6 of 8) Chapter 2 Removal and replacement ENWW...

  • Page 269

    Release two pins and the front of the assembly. Figure 2-177 Remove the registration assembly (7 of 8) Remove the assembly from the product. Reinstallation tip When you reinstall the registration assembly, make sure that it is correctly positioned in the product. The tabs on the assembly must fit into the slots in the product chassis and the assembly fits securely up against the product chassis.

  • Page 270: Residual-toner-feed Motor

    Residual-toner-feed motor Before proceeding, remove the following components: Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124.

  • Page 271: Residual-toner Duct And Feed Assembly

    Residual-toner duct and feed assembly Before proceeding, remove the following components: Toner-collection unit. See Toner-collection unit on page 104. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Standard output bin. See Standard output bin on page 123.

  • Page 272

    Release one tab, and then remove the waste toner duct. Figure 2-181 Remove the residual-toner duct and feed assembly (2 of 4) Remove one screw. Figure 2-182 Remove the residual-toner duct and feed assembly (3 of 4) Chapter 2 Removal and replacement ENWW...

  • Page 273

    Push the residual-toner feed assembly into the product and then remove through the print cartridge cavity. CAUTION: The waste toner feed assembly contains toner. Place a cloth below the work area to catch any spilled toner. Figure 2-183 Remove the residual-toner duct and feed assembly (4 of 4) Internal assemblies ENWW...

  • Page 274: Cartridge Fan And Environmental Sensor

    Cartridge fan and environmental sensor Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124. ● Fan cover. See Fan cover on page 134.

  • Page 275

    Release one spring. TIP: Close the front-door assembly to reduce tension in the spring. Figure 2-185 Remove the cartridge fan and environmental sensor (2 of 7) Release one tab and then slide the fan assembly toward the back of the product. Figure 2-186 Remove the cartridge fan and environmental sensor (3 of 7) Internal assemblies...

  • Page 276

    Pull the fan assembly out of the product, and then disconnect two connectors. TIP: One connector is below the sponge. Figure 2-187 Remove the cartridge fan and environmental sensor (4 of 7) Release two tabs (callout 1), and then remove the cover (callout 2). Figure 2-188 Remove the cartridge fan and environmental sensor (5 of 7) Chapter 2 Removal and replacement...

  • Page 277

    Disconnect one connector (callout 1), and then remove the fan (callout 2). Figure 2-189 Remove the cartridge fan and environmental sensor (6 of 7) Carefully release one tab, and then remove the environmental sensor. CAUTION: ESD-sensitive part. Figure 2-190 Remove the cartridge fan and environmental sensor (7 of 7) Internal assemblies ENWW...

  • Page 278: Toner-collection Sensor And Scanner-thermistor Assembly

    Toner-collection sensor and scanner-thermistor assembly Before proceeding, remove the following components: Toner-collection unit. See Toner-collection unit on page 104. ● Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124.

  • Page 279

    Open the front-door assembly, and then remove one screw. Figure 2-192 Remove the toner-collection sensor and scanner-thermistor assembly (2 of 3) Disconnect two connectors (callout 1), and then remove the toner-collection sensor and scanner- thermistor assembly (callout 2). Figure 2-193 Remove the toner-collection sensor and scanner-thermistor assembly (3 of 3) Internal assemblies ENWW...

  • Page 280: Delivery Fan

    Delivery fan Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 281: Intermediate Cover And Duplexing Gear Cover

    Intermediate cover and duplexing gear cover Before proceeding, remove the following components: S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Document feeder. See Document feeder on page 151. ● Scanner assembly. See Scanner assembly on page 171.

  • Page 282

    Rotate the intermediate cover and remove. Figure 2-196 Remove the intermediate cover and duplexing gear cover (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 283: Delivery Assembly, Remove The Delivery Assembly

    Delivery assembly Before proceeding, remove the following components: Fuser. See Fuser on page 112. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124.

  • Page 284

    Pull one tab out, and then push the tab down to release the bushing. Figure 2-198 Remove the delivery assembly (2 of 4) NOTE: When reinstalling, make sure the tab is correctly installed and flush against the chassis. Remove two screws. Figure 2-199 Remove the delivery assembly (3 of 4) Chapter 2 Removal and replacement...

  • Page 285

    Remove the assembly. Figure 2-200 Remove the delivery assembly (4 of 4) Internal assemblies ENWW...

  • Page 286: Reinstall The Delivery Assembly

    Reinstall the delivery assembly Make sure that the solenoid plunger is correctly installed on the replacement assembly. ▲ Figure 2-201 Reinstall the delivery assembly Chapter 2 Removal and replacement ENWW...

  • Page 287: Duplex-drive Assembly

    Duplex-drive assembly Before proceeding, remove the following components: Fuser. See Fuser on page 112. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124.

  • Page 288: Power-supply Fan

    Power-supply fan Before proceeding, remove the following components: Standard output bin. See Standard output bin on page 123. ● Output bin bezel. See Output bin bezel on page 124. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 289: Image Scanner Power Supply Unit (psu)

    Release one tab (callout 1), and then remove the fan (callout 2) from the fan duct. Reinstallation tip When the fan is reinstalled, the air must flow into the product. Check the arrows embossed on the fan frame that indicate air flow direction. Figure 2-204 Remove the power-supply fan (2 of 2) Image scanner power supply unit (PSU)

  • Page 290: Remove The Image Scanner Supply Unit (psu) And Fan

    Remove the image scanner supply unit (PSU) and fan Disconnect three connectors (callout 1), remove three screws (callout 2), and then remove the image scanner supply unit (PSU). Figure 2-205 Remove the image scanner supply unit (PSU) and fan (1 of 2) Remove one screw, disconnect one connector, and then remove the fan.

  • Page 291: Interconnect Board (icb)

    Failure to follow this warning will result in severe damage to that product and cause it to be unusable. HP recommends that if you remove and replace the ICB, you should destroy the discarded ICB so that it can not accidentally be installed in a different product.

  • Page 292

    Carefully rotate and slide the ICB up and away from the chassis, disconnect one connector, and then remove the ICB. Figure 2-208 Remove the ICB (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 293: Dc Controller Pca Only

    DC controller PCA only NOTE: Use the following procedure to replace only the DC controller PCA. To access components behind the DC controller, remove the PCA and the sheet-metal backing tray. See DC controller PCA and tray on page 248. Before proceeding, remove the following components: Standard output bin.

  • Page 294

    Disconnect all the connectors. Remove four screws and then remove the DC controller PCA ▲ Reinstallation tip The connector locations J101 and J102 are not used. Figure 2-209 Remove the DC controller PCA only Chapter 2 Removal and replacement ENWW...

  • Page 295: Low-voltage Power Supply (lvps)

    Low-voltage power supply (LVPS) Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Lower-left cover. See Lower-left cover on page 136. ● Fan cover.

  • Page 296

    Disconnect five connectors, and then release the wire harnesses from the guides as necessary. NOTE: To locate DC controller connector locations, see DC controller connector locations on page 432. Figure 2-211 Remove the low-voltage power supply (2 of 8) Disconnect one connector, and then release the wire harness from the guide. Reinstallation tip Make sure that you reconnect this connector when the power supply is reinstalled.

  • Page 297

    Remove three screws. Figure 2-213 Remove the low-voltage power supply (4 of 8) Remove three screws. Figure 2-214 Remove the low-voltage power supply (5 of 8) Internal assemblies ENWW...

  • Page 298

    Slide the end of the formatter cage away from the product (callout 1) and the slide the cage out of the product (callout 2). Figure 2-215 Remove the low-voltage power supply (6 of 8) Remove two screws. Figure 2-216 Remove the low-voltage power supply (7 of 8) Chapter 2 Removal and replacement ENWW...

  • Page 299

    Slide and then lift the end of low-voltage power supply until it is free of the product. Remove the low-voltage power supply. Figure 2-217 Remove the low-voltage power supply (8 of 8) Internal assemblies ENWW...

  • Page 300: Dc Controller Pca And Tray

    DC controller PCA and tray Before proceeding, remove the following components: S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Lower-left cover. See Lower-left cover on page 136. ● Fan cover. See Fan cover on page 134.

  • Page 301

    Remove two screws. Figure 2-219 Remove the DC controller PCA and tray (2 of 3) Disengage three tabs (two along the left edge of the PCA and one at the top-right corner of the PCA). Figure 2-220 Remove the DC controller PCA and tray (3 of 3) Internal assemblies ENWW...

  • Page 302: High-voltage Power Supply Lower (hvps-d)

    High-voltage power supply lower (HVPS-D) Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ●...

  • Page 303

    Remove three screws. Figure 2-222 Remove the high-voltage power supply lower (2 of 7) Internal assemblies ENWW...

  • Page 304

    Release four locking clips. NOTE: Squeeze each locking clip to remove. Figure 2-223 Remove the high-voltage power supply lower (3 of 7) Figure 2-224 Remove the high-voltage power supply lower (4 of 7) Chapter 2 Removal and replacement ENWW...

  • Page 305

    Release five tabs. Figure 2-225 Remove the high-voltage power supply lower (5 of 7) Rotate the top of the power supply away from the chassis, and then disconnect two connectors on the back of the power supply. NOTE: Do not disconnect the FFC (callout 1). The FFC and the FFC wiring guide are supplied with the replacement assembly.

  • Page 306: Reinstall The High-voltage Power Supply Lower

    Disconnect one FFC (callout 1). Release only the wire harnesses from the guide (callout 2) and then remove the power supply. Figure 2-227 Remove the high-voltage power supply lower (7 of 7) Reinstall the high-voltage power supply lower When you reinstall the power supply, look through the holes in the PCA and make sure that the high- voltage contact springs are correctly seated against the PCA.

  • Page 307: Developing-disengagement Motor

    Developing-disengagement motor Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ● Lower-left cover. See Lower-left cover on page 136.

  • Page 308: Exhaust Fan And Fan Duct

    Exhaust fan and fan duct Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ●...

  • Page 309

    Release five tabs (callout 1) and remove the cover (callout 2). Figure 2-231 Remove the exhaust fan and fan duct (2 of 3) Disconnect one connector, and then remove the fan from the duct. Figure 2-232 Remove the exhaust fan and fan duct (3 of 3) Internal assemblies ENWW...

  • Page 310: Reinstall The Exhaust Fan And Fan Duct

    Reinstall the exhaust fan and fan duct Be sure that the toroid (callout 1) is correctly aligned in the FFC cable guide before attempting to reinstall the exhaust fan and duct. Figure 2-233 Reinstall the exhaust fan and fan duct Chapter 2 Removal and replacement ENWW...

  • Page 311: Pickup Motor

    Pickup motor Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ● Lower-left cover. See Lower-left cover on page 136.

  • Page 312: Lifter-drive Assembly

    Lifter-drive assembly Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 313: Remove The Lifter-drive Assembly

    Remove the lifter-drive assembly Remove one screw (callout 1), and then move the accessory-tray connector (callout 2) to access the screw behind it. Reinstallation tip If the product is installed on the optional paper feeder, you must slightly separate the product and the feeder assembly to install this connector. Open the right door on the feeder.

  • Page 314

    Remove the lifter-drive assembly from the product. CAUTION: The spring on the assembly is not captive. Do not lose the spring when the assembly is removed. Figure 2-237 Remove the lifter-drive assembly (3 of 3) NOTE: Make sure that the lifter-drive assembly moves up and down easily after reinstalling. Chapter 2 Removal and replacement ENWW...

  • Page 315: Lifter Base Assembly

    Lifter base assembly Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106 ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Lower-left cover. See Lower-left cover on page 136. ● Fan cover. See Fan cover on page 134.

  • Page 316: Reinstall The Lifter Base Assembly

    From inside the Tray 2 cavity, remove four screws, and then remove the lifter base assembly. NOTE: Pull the assembly straight from the product without tipping to prevent the spring from falling from the assembly. Reinstallation tip If the tray does not completely close when reinstalled, push on the lever in the opening (callout 1) with a flat blade screwdriver to reset the spring in the closing mechanism.

  • Page 317

    Place the spring in the lifter before installing the assembly on the product. Figure 2-241 Reinstall the lifter base assembly (2 of 2) Internal assemblies ENWW...

  • Page 318: Tray-pickup Drive Assembly

    Tray-pickup drive assembly Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Lower-left cover. See Lower-left cover on page 136. ● Left cover. See Left cover on page 137.

  • Page 319

    Remove two screws (callout 1), disconnect one connector (callout 2), and then remove the pickup motor (callout 35). Figure 2-243 Remove the tray-pickup drive assembly (2 of 3) Remove three screws, and then remove the tray-pickup drive assembly. NOTE: The cams on the main-drive assembly can prevent the tray-pickup drive assembly from releasing from the product.

  • Page 320: Tray-pickup Assembly

    Tray-pickup assembly Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 321: Remove The Tray-pickup Assembly

    Remove the tray-pickup assembly NOTE: This task requires that you remove three feed guides on the right side of the product before you can remove the tray-pickup assembly. Remove one screw (callout 1), and then disconnect two connectors (callout 2). Figure 2-245 Remove the tray-pickup assembly (1 of 11) From the front of the product, remove one screw (callout 1), and then remove one tray rail...

  • Page 322

    From the right side of the product, remove two screws (callout 1) and one cover (callout 2). Figure 2-247 Remove the tray-pickup assembly (3 of 11) Close the right-door assembly. Push in and then push up on the stopper to release. Figure 2-248 Remove the tray-pickup assembly (4 of 11) Chapter 2 Removal and replacement...

  • Page 323

    Open the right-door assembly. Lift the two link arms (callout 1) to release from the product, and then remove the paper guide (callout 2). Figure 2-249 Remove the tray-pickup assembly (5 of 11) Close the right-door assembly. Push the two tabs toward each other, and then push up to release the feed guide.

  • Page 324

    Open the right-door assembly, and then remove the feed guide. Figure 2-251 Remove the tray-pickup assembly (7 of 11) Remove two screws (callout 1), and then remove two brackets (callout 2). Figure 2-252 Remove the tray-pickup assembly (8 of 11) Chapter 2 Removal and replacement ENWW...

  • Page 325

    Release one tab (callout 1), and then slide the feed guide (callout 2) toward the front of the product to remove. Figure 2-253 Remove the tray-pickup assembly (9 of 11) Remove one screw. Figure 2-254 Remove the tray-pickup assembly (10 of 11) Internal assemblies ENWW...

  • Page 326

    Remove the tray-pickup assembly. Figure 2-255 Remove the tray-pickup assembly (11 of 11) Chapter 2 Removal and replacement ENWW...

  • Page 327: Laser/scanner Assembly (y/m)

    Laser/scanner assembly (Y/M) Before proceeding, remove the following components: Toner collection unit. See Toner-collection unit on page 104. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 328: Remove The Laser/scanner Assembly (y/m)

    Remove the laser/scanner assembly (Y/M) NOTE: After installing a new laser/scanner assembly, be sure to calibrate the product. See Calibrate the product on page 468. Release one spring. CAUTION: The spring is not captive. Do not lose the spring when it is removed. Use a pair of needle-nose pliers to safely retain the spring when it is removed.

  • Page 329

    Release one spring (callout 1), and then disconnect one FFC (callout 2). Reinstallation tip When reinstalled, the toroid (callout 3) must be correctly positioned on the wire guide (in the provided slots) so that the fan duct will fully seat in the product when it is reinstalled.

  • Page 330

    Rotate the front of the laser/scanner assembly down (callout 1), and then slide it toward the right (callout 2). Lower the left corner, and then rotate the left corner out of the product (callout 3). Reinstallation tip When the scanner is reinstalled, make sure that the tab on the front of the laser/scanner is inserted in the alignment hole in the product chassis.

  • Page 331: Laser/scanner Assembly (c/bk)

    Laser/scanner assembly (C/Bk) Before proceeding, remove the following components: Toner collection unit. See Toner-collection unit on page 104. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128.

  • Page 332: Remove The Laser/scanner Assembly (c/bk)

    Remove the laser/scanner assembly (C/Bk) NOTE: After installing a new laser/scanner assembly, be sure to calibrate the product. See Calibrate the product on page 468. Release one spring (callout 1), and then disconnect one FFC (callout 2). CAUTION: The spring is not captive. Do not lose the spring when it is removed. Use a pair of needle-nose pliers to safely retain the spring when it is removed.

  • Page 333

    Disconnect one connector. Figure 2-262 Remove the laser/scanner assembly (C/Bk) (2 of 5) Remove five screws (callout 1), and then remove the cover (callout 2). CAUTION: Be careful. The PGC actuators are easily dislodged when the cover is removed. See Figure 2-266 Reinstall the PGC actuators (1 of 5) on page 283.

  • Page 334

    Release one spring. CAUTION: The spring is not captive. Do not lose the spring when it is removed. Use a pair of needle-nose pliers to safely retain the spring when it is removed. Do not use a flat blade screwdriver to remove the spring; the spring could forcibly leave the product and strike you. Reinstallation tip When you reinstall the spring, make sure that the laser/scanner fits tightly up against the product chassis.

  • Page 335: Reinstall The Protective Glass Cleaner (pgc) Actuators

    Rotate the corner of the assembly away from the product until you can see the PCA, and then remove the assembly from the product. Reinstallation tip When the laser/scanner is correctly positioned in the chassis, the plastic parts which protrude at the front and rear of the product will be firmly seated against the locator tabs on the chassis.

  • Page 336

    Remove the actuator and spring from the product. Install the spring on the actuator. Figure 2-267 Reinstall the PGC actuators (2 of 5) Before proceeding, take note of the following: Callout 1: The pin on the actuator will be installed into the slot in the chassis. ●...

  • Page 337

    Place the end of the actuator into the PGC rod, and then use a small flat blade screw driver to fasten the end of the spring on the tab on the chassis. Figure 2-269 Reinstall the PGC actuators (4 of 5) Push down on the actuator to seat it into place.

  • Page 338: High-voltage Power Supply Upper (hvps-t)

    High-voltage power supply upper (HVPS-T) Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ●...

  • Page 339

    Disconnect one connector (callout 1) and then remove the power supply.Do not disconnect two connectors (callout 2) Figure 2-272 Remove the high-voltage power supply upper (1 of 2) Internal assemblies ENWW...

  • Page 340: Reinstall The High-voltage Power Supply Upper

    Reinstall the high-voltage power supply upper When you reinstall the power supply, look through the holes in the PCA and make sure that the high- voltage contact springs are correctly seated against the PCA. NOTE: For a replacement power supply, remove one wire harness (callout 1) and then install it on the replacement power supply.

  • Page 341: Yellow, Magenta, Cyan, And Black Drum Motors

    Yellow, magenta, cyan, and black drum motors Before proceeding, remove the following components: S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ● Lower-left cover. See Lower-left cover on page 136.

  • Page 342: Fuser Motor

    Fuser motor Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Lower-left cover. See Lower-left cover on page 136. ● Fan cover. See Fan cover on page 134.

  • Page 343: Remove The Fuser Motor

    Remove the fuser motor Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor (callout 3). Figure 2-275 Remove the fuser motor Internal assemblies ENWW...

  • Page 344: Itb Motor

    ITB motor Before proceeding, remove the following components: S-CVR-REAR (scanner rear cover). See S-CVR-REAR (scanner rear cover) on page 128. ● Fan cover. See Fan cover on page 134. ● Lower-left cover. See Lower-left cover on page 136. ● Left cover. See Left cover on page 137.

  • Page 345: Main-drive Assembly

    Main-drive assembly NOTE: Removing the main-drive assembly typically requires more than 2 hours to complete. Before proceeding, remove the following components: Formatter. See Formatter PCA on page 106. ● Intermediate transfer belt (ITB). See Intermediate transfer belt (ITB) on page 120.

  • Page 346: Remove The Main-drive Assembly

    Remove the main-drive assembly Remove one screw and then release the fan from the chassis. Figure 2-277 Remove the main-drive assembly (1 of 7) Remove eight connectors (callout 1), and then release the wire harnesses from the guides (callout 2). NOTE: Leave the wire harnesses with the product.

  • Page 347

    Remove two screws (callout 1), disconnect one connector (callout 2), and then remove the developing-disengagement motor. NOTE: When the motor is reinstalled, make sure the motor PCA is positioned at the top of the assembly. Figure 2-279 Remove the main-drive assembly (3 of 7) Remove one screw (callout 1), and then remove the wire guide from the main-drive assembly (callout 2).

  • Page 348

    Remove 10 screws. Figure 2-281 Remove the main-drive assembly (5 of 7) Separate the main-drive assembly from the product. Figure 2-282 Remove the main-drive assembly (6 of 7) Chapter 2 Removal and replacement ENWW...

  • Page 349

    Release the wire harness (callout 1) from the guides, and then remove the main-drive assembly from the product. Reinstallation tip It might be easier to pass this harness over the edge of the assembly chassis after the main-drive assembly is reinstalled. Figure 2-283 Remove the main-drive assembly (7 of 7) CAUTION:...

  • Page 350: Reinstall The Main-drive Assembly

    Reinstall the main-drive assembly Locate the cams (callout 1) on the back side of the assembly. Figure 2-284 Reinstall the main-drive assembly (1 of 7) Slowly rotate the shaft near the black cam. WARNING! Do not touch the plastic gears or cams. You must not wipe away any of the grease that is applied to these components.

  • Page 351

    Continue to rotate the shaft until the holes in the black-cam gear align as shown below. When correctly aligned, the bottom-most hole in the gear is aligned with a hole in the sheet-metal chassis. NOTE: The holes in the other cam gears have a different alignment. You must make sure that the holes in the black-cam gear are correctly aligned.

  • Page 352

    Verify that the cams (callout 1) align correctly. TIP: The second cam in from the right (the white cam to the left of the black cam), should have the second hole aligned with the hole in the sheet-metal chassis. The third cam in from the right, should have the third hole aligned with the hole in the sheet-metal chassis.

  • Page 353

    When the cams align correctly, they easily fit into the holes in the chassis. Figure 2-288 Reinstall the main-drive assembly (5 of 7) When placing the assembly on the chassis, align the holes in the assembly with the holes in the chassis.

  • Page 354

    When the assembly is correctly installed, the tabs are flat against the chassis. Figure 2-290 Reinstall the main-drive assembly (7 of 7) TIP: After reassembling the product, use the Diagnostics menu to print a Color Band Test page. If the test page shows one or more color planes are not printing (usually in the upper left corner of the page), the cam or cams for the missing color plane are not correctly aligned.

  • Page 355: Front Door (optional Paper Feeder)

    Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) NOTE: For information about removing the Tray 3, 4, or 5 feed and separation rollers, see Feed and separation rollers (Trays 2-5) on page 113. For information about removing the Tray 3, 4, or 5 cassettes, see Tray on page 111.

  • Page 356

    Release the link arm (callout 1), and then remove the front door (callout 2). Figure 2-292 Remove the front door (optional paper feeder) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 357: Rear Cover (optional Paper Feeder)

    Rear cover (optional paper feeder) Remove two screws (callout 1), and then remove the rear cover (callout 2). ▲ Figure 2-293 Remove the rear cover (optional paper feeder) Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) ENWW...

  • Page 358: Right-front Cover (optional Paper Feeder)

    Right-front cover (optional paper feeder) Open the front and right doors, remove one screw (callout 1), and then lift the right-front cover ▲ (callout 2) to remove. Figure 2-294 Remove the right-front cover (optional paper feeder) Chapter 2 Removal and replacement ENWW...

  • Page 359: Right Door (optional Paper Feeder)

    Right door (optional paper feeder) Open the right door, release one tab (callout 1), and then remove the stopper (callout 2) Figure 2-295 Remove the right door (optional paper feeder) (1 of 3) Close the right door slightly, and then release the upper link arm. Figure 2-296 Remove the right door (optional paper feeder) (2 of 3) Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet)

  • Page 360

    Slide the door to release the lower link arm, and then remove the right door. Figure 2-297 Remove the right door (optional paper feeder) (3 of 3) Chapter 2 Removal and replacement ENWW...

  • Page 361: Left Cover (optional Paper Feeder)

    Left cover (optional paper feeder) Before proceeding, remove the following components: Front door (optional paper feeder). See Front door (optional paper feeder) on page 303. ● Right-front cover (optional paper feeder). See Right-front cover (optional paper feeder) ● on page 306.

  • Page 362

    1 x 500 paper feeder only: Remove three screws (callout 1), and then remove the storage box (callout 2). Figure 2-299 Remove the left cover (optional paper feeder) (2 of 3) Release five tabs (callout 1), and then remove the left cover (callout 2). Figure 2-300 Remove the left cover (optional paper feeder) (3 of 3) Chapter 2 Removal and replacement...

  • Page 363: Right Cover (optional Paper Feeder)

    Right cover (optional paper feeder) Before proceeding, remove the following components: Right door (optional paper feeder). See Right door (optional paper feeder) on page 307. ● Remove the right cover (optional paper feeder) Remove two screws (callout 1), release one tab (callout 2), and then remove the right cover ▲...

  • Page 364: Rear-right Cover (optional Paper Feeder)

    Rear-right cover (optional paper feeder) Before proceeding, remove the following components: Right door (optional paper feeder). See Right door (optional paper feeder) on page 307. ● Remove the rear-right cover (optional paper feeder) Remove one screw (callout 1), and then lift the rear-right cover (callout 2) to remove. ▲...

  • Page 365: Pickup Assembly (optional Paper Feeder)

    Pickup assembly (optional paper feeder) Before proceeding, remove the following components: Paper feeder right front cover. See Right-front cover (optional paper feeder) on page 306. ● Paper feeder rear cover. See Rear cover (optional paper feeder) on page 305. ● NOTE: The following procedure shows steps for removing the pickup assembly for Tray 3.

  • Page 366

    1 x 500-sheet optional paper feeder only: Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor assembly (callout 3). Figure 2-304 Remove the pickup assembly (optional paper feeder) (2 of 5) 3 x 500-sheet optional paper feeder only: Remove four screws (callout 1), disconnect two connector (callout 2), and then remove the motor assembly (callout 3).

  • Page 367

    Remove one screw (callout 1), and then disconnect three connectors (callout 2). Figure 2-306 Remove the pickup assembly (optional paper feeder) (4 of 5) Remove one screw (callout 1), and then remove the pickup assembly (callout 2). Figure 2-307 Remove the pickup assembly (optional paper feeder) (5 of 5) Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) ENWW...

  • Page 368: Lifter Assembly (optional Paper Feeder)

    Lifter assembly (optional paper feeder) Before proceeding, remove the following components: Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 305. ● Remove the lifter assembly (optional paper feeder) Disconnect one connector (callout 1). Figure 2-308 Remove the lifter assembly (optional paper feeder) (1 of 2) Remove four screws (callout 1), and then remove the lifter assembly (callout 2).

  • Page 369: Lifter-drive Assembly (optional Paper Feeder)

    Lifter-drive assembly (optional paper feeder) Before proceeding, remove the following components: Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 305. ● Remove the lifter-drive assembly (optional paper feeder) Disconnect one connector (callout 1), and then release the wire harnesses (callout 3) from the guides (callout 2).

  • Page 370: Pickup Motor Assembly (optional Paper Feeder)

    Pickup motor assembly (optional paper feeder) Before proceeding, remove the following components: Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 305. ● Remove the pickup motor (optional paper feeder) assembly 1 x 500-sheet optional paper feeder only: Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor assembly (callout 3).

  • Page 371: Controller Pca (optional Paper Feeder)

    Controller PCA (optional paper feeder) Before proceeding, remove the following components: Rear cover (optional paper feeder). See Rear cover (optional paper feeder) on page 305. ● Remove the controller PCA (optional paper feeder) CAUTION: ESD-sensitive part. 1 x 500-sheet optional paper feeder only: Disconnect four connector (callout 2), and then remove two screws (callout 1).

  • Page 372

    3 x 500-sheet optional paper feeder only: Disconnect all connectors, and then remove two screws (callout 1). Release three tabs (callout 2), and then remove the PCA (callout 3). Figure 2-315 Remove the controller PCA (optional paper feeder) (2 of 2) Chapter 2 Removal and replacement ENWW...

  • Page 373: Rear Cover (500-sheet Paper Feeder)

    Optional 500-sheet paper feeder assembly For information about removing the optional paper feeder assemblies (1 x 500-sheet and 3 x 500- sheet), see Optional paper feeder assemblies (1 x 500-sheet and 3 x 500-sheet) on page 303 Rear cover (500-sheet paper feeder) Remove two screws (callout 1), and then remove the rear cover (callout 2).

  • Page 374: Left Cover (500-sheet Paper Feeder)

    Left cover (500-sheet paper feeder) Before proceeding, remove the following components: Rear cover (500-sheet paper feeder). See Rear cover (500-sheet paper feeder) on page 321. ● Remove the left cover (500-sheet paper feeder) Release three tabs. Figure 2-318 Remove the left cover (500-sheet paper feeder) (1 of 2) Pull the top of the cover out (callout 1), and then press down (callout 2) to remove the cover.

  • Page 375: Right Cover (500-sheet Paper Feeder)

    Right cover (500-sheet paper feeder) Before proceeding, remove the following components: Right front cover (500-sheet paper feeder). See Right-front cover (500-sheet paper feeder) ● on page 321. Remove the right cover (500-sheet paper feeder) Remove two screws (callout 1), release one tab (callout 2), and then remove the right cover (callout 3).

  • Page 376: Front Cover (500-sheet Paper Feeder)

    Front cover (500-sheet paper feeder) Remove three screws (callout 1), release two tabs (callout 2), and then remove the front cover. ▲ Figure 2-322 Remove the rear-right cover (500-sheet paper feeder) Chapter 2 Removal and replacement ENWW...

  • Page 377: Pickup Assembly (500-sheet Paper Feeder)

    Pickup assembly (500-sheet paper feeder) Before proceeding, remove the following components: Right front cover (500-sheet paper feeder). See Right-front cover (500-sheet paper feeder) ● on page 321. Right cover (500-sheet paper feeder). See Right cover (500-sheet paper feeder) on page 323 ●...

  • Page 378

    Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor assembly (callout 3). Figure 2-324 Remove the pickup assembly (500-sheet paper feeder) (2 of 5) Remove one screw (callout 1), and then disconnect three connectors (callout 2). Figure 2-325 Remove the pickup assembly (500-sheet paper feeder) (3 of 5) Chapter 2 Removal and replacement...

  • Page 379

    Remove one screw. Figure 2-326 Remove the pickup assembly (500-sheet paper feeder) (4 of 5) Move the top of the assembly to the right (callout 1) until the post (callout 4) is free of the hole. Lift the assembly (callout 2), and then pull the bottom of the assembly (callout 3) to remove. Figure 2-327 Remove the pickup assembly (500-sheet paper feeder) (5 of 5) Optional 500-sheet paper feeder assembly...

  • Page 380: Lifter Assembly (500-sheet Paper Feeder)

    Lifter assembly (500-sheet paper feeder) Before proceeding, remove the following components: Rear cover (500-sheet paper feeder). See Rear cover (500-sheet paper feeder) on page 321. ● Remove the lifter assembly (500-sheet paper feeder) Disconnect one connector (callout 1). Figure 2-328 Remove the lifter assembly (500-sheet paper feeder) (1 of 2) Remove four screws (callout 1), and then remove the lifter assembly (callout 2).

  • Page 381: Reinstall The Lifter Assembly

    Reinstall the lifter assembly If the spring falls from the lifter assembly, reinstall it in the lifter before reinstalling the lifter assembly. Reinstall the lifter assembly Place the spring in the lifter before installing the assembly on the product. ▲ Figure 2-330 Reinstall the lifter assembly (500-sheet paper feeder) Optional 500-sheet paper feeder assembly...

  • Page 382: Lifter-drive Assembly (500-sheet Paper Feeder)

    Lifter-drive assembly (500-sheet paper feeder) Before proceeding, remove the following components: Rear cover (500-sheet paper feeder). See Rear cover (500-sheet paper feeder) on page 321. ● Remove the lifter-drive assembly (500-sheet paper feeder) Disconnect one connector (callout 1), and then release the wire harnesses (callout 3) from the guides (callout 2).

  • Page 383: Pickup Motor Assembly (500-sheet Paper Feeder)

    Pickup motor assembly (500-sheet paper feeder) Before proceeding, remove the following components: Rear cover (500-sheet paper feeder). See Rear cover (500-sheet paper feeder) on page 321. ● Remove the pickup motor (500-sheet paper feeder) assembly Remove three screws (callout 1), disconnect one connector (callout 2), and then remove the motor ▲...

  • Page 384: Controller Pca (500-sheet Paper Feeder)

    Controller PCA (500-sheet paper feeder) Before proceeding, remove the following components: Rear cover (500-sheet paper feeder). See Rear cover (500-sheet paper feeder) on page 321. ● Remove the controller PCA (500-sheet paper feeder) CAUTION: ESD-sensitive part. Disconnect all connectors, and then remove two screws (callout 1). Release three tabs (callout 2), ▲...

  • Page 385: Stapling Mailbox

    Stapling mailbox This section provides stapling mailbox removal and replacement procedures. NOTE: The stapling mailbox is also referred to as the SSMBM. Stapling mailbox front cover Open the stapling mailbox door, remove one screw (callout 1), release two tabs (callout 2), and ▲...

  • Page 386: Stapling Mailbox Rear Cover

    Stapling mailbox rear cover Remove two screws (callout 1), release one tab (callout 2), and then remove the rear cover (callout ▲ Figure 2-336 Remove the stapling mailbox rear cover Chapter 2 Removal and replacement ENWW...

  • Page 387: Stapling Mailbox Door

    Stapling mailbox door Remove the following components or assemblies: Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Remove three screws (callout 1), and then remove the stapling mailbox door (callout 2). Figure 2-337 Remove the stapling mailbox door Holder connector Before proceeding, remove the following components: Stapling mailbox rear cover.

  • Page 388: Remove The Holder Connector

    Remove the holder connector Remove one screw, and then remove the holder connector. ▲ Figure 2-338 Remove the holder connector Chapter 2 Removal and replacement ENWW...

  • Page 389: Top Cover, Remove The Top Cover

    Top cover Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Remove the top cover Remove one screw (callout 1), and then remove the top cover (callout 2). ▲...

  • Page 390: Output Bin

    Output bin 3 Squeeze and pull two stoppers to remove from the output bin. Figure 2-340 Remove the output bin (1 of 3) NOTE: When reinstalling the output bin, make sure the two stoppers are installed in the correct position. Figure 2-341 Remove the output bin (2 of 3) Chapter 2 Removal and replacement...

  • Page 391

    Release two tabs (callout 1) and slide the output bin (callout 2) to remove. Figure 2-342 Remove the output bin (3 of 3) Stapling mailbox ENWW...

  • Page 392: Stapling Mailbox Pca

    Stapling mailbox PCA CAUTION: ESD-sensitive part. Remove two screws. Figure 2-343 Remove the stapling mailbox PCA (1 of 5) Remove the PCA cover. Figure 2-344 Remove the stapling mailbox PCA (2 of 5) Chapter 2 Removal and replacement ENWW...

  • Page 393

    Release the cables (callout 2) from the cable guide (callout 1). Figure 2-345 Remove the stapling mailbox PCA (3 of 5) NOTE: Be careful not to damage components (callout 3) on the PCA. Figure 2-346 Remove the stapling mailbox PCA (4 of 5) Stapling mailbox ENWW...

  • Page 394

    Remove two screws (callout 1), disconnect all connectors from the PCA, and then remove the PCA. Figure 2-347 Remove the stapling mailbox PCA (5 of 5) NOTE: There is no connection for J460. Chapter 2 Removal and replacement ENWW...

  • Page 395: Stapler Assembly

    Stapler assembly Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Remove the stapler assembly Remove three screws (callout 1), disconnect two connectors (callout 2), and then remove the ▲ stapler assembly (callout 3).

  • Page 396: Stamp Solenoid

    Stamp solenoid Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox PCA. See Stapling mailbox PCA on page 340. ● Stapler assembly. See Stapler assembly on page 343. ●...

  • Page 397

    Remove two screws (callout 1), and then remove the stamp solenoid (callout 2). Figure 2-350 Remove the stamp solenoid (2 of 2) Stapling mailbox ENWW...

  • Page 398: Output Bin Sensor Pca

    Output bin sensor PCA Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Remove the output bin sensor PCA CAUTION: ESD-sensitive part. Remove one screw (callout 1) and disconnect one connector (callout 2). Figure 2-351 Remove the output bin sensor PCA (1 of 2) Chapter 2 Removal and replacement...

  • Page 399

    Release two tabs (callout 1), clear one post (callout 2), and slide the PCA to remove (callout 3). Figure 2-352 Remove the output bin sensor PCA (2 of 2) CAUTION: Be careful not to damage the flags (callout 4) when removing and installing the PCA.

  • Page 400: Stacking Panel

    Stacking panel Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Output bin 3. See Output bin 3 on page 338.

  • Page 401

    Remove the PCA cover. Figure 2-354 Remove the output bin 3 drive assembly (2 of 3) Release two tabs (callout 1) and them remove the stacking panel (callout 2). Figure 2-355 Remove the output bin 3 drive assembly (3 of 3) Stapling mailbox ENWW...

  • Page 402: Jogger Assembly

    Jogger assembly Before proceeding, remove the following components: Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Remove the jogger assembly Disconnect two connectors (callout 1).

  • Page 403

    Remove one screw. Figure 2-357 Remove the jogger assembly (2 of 3) Disengage pin and remove the jogger assembly. Figure 2-358 Remove the jogger assembly (3 of 3) Stapling mailbox ENWW...

  • Page 404: Flapper Guide Assembly

    Flapper guide assembly Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Stapling mailbox door. See Stapling mailbox door on page 335.

  • Page 405: Remove The Flapper Guide Assembly

    Remove the flapper guide assembly Remove two screws (callout 1), release one tab (callout 2), and then remove the flapper guide ▲ assembly (callout 3). Figure 2-359 Remove the flapper guide assembly (1 of 2) NOTE: Make sure to reinstall the stepped screw on the left side of the assembly. NOTE: When reinstalling the assembly, makes sure to correctly reattach the two pieces of the assembly.

  • Page 406: Flapper Assembly

    Flapper assembly Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Stapling mailbox door. See Stapling mailbox door on page 335.

  • Page 407: Remove The Flapper Assembly

    Remove the flapper assembly Remove one tab (callout 1), release the solenoid arm (callout 2), and then remove the flapper ▲ assembly (callout 3). Figure 2-361 Remove the flapper guide assembly (1 of 2) NOTE: When reinstalling the assembly, makes sure to correctly reattach the solenoid and arm. Figure 2-362 Remove the flapper guide assembly (2 of 2) Stapling mailbox...

  • Page 408: Mbm Output Bin Assembly

    MBM output bin assembly Before proceeding, remove the following components: Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Stapling mailbox door. See Stapling mailbox door on page 335. ● Top cover. See Top cover on page 337.

  • Page 409

    Remove two screws. Figure 2-364 Remove the MBM output bin assembly (2 of 3) Remove the belt and then the assembly. Figure 2-365 Remove the MBM output bin assembly (3 of 3) Stapling mailbox ENWW...

  • Page 410: Output Bin 3 Drive Assembly

    Output bin 3 drive assembly Before proceeding, remove the following components: Stapling mailbox front cover. See Stapling mailbox front cover on page 333. ● Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Output bin 3. See Output bin 3 on page 338.

  • Page 411

    Disconnect two connectors. Figure 2-367 Remove the output bin 3 drive assembly (2 of 4) Using a screwdriver to disengage the gear (callout 1) and then slide the tray support (callout 2) to remove it. Figure 2-368 Remove the output bin 3 drive assembly (3 of 4) Stapling mailbox ENWW...

  • Page 412

    Remove four screws and then remove the output bin 3 drive assembly. Figure 2-369 Remove the output bin 3 drive assembly (4 of 4) Chapter 2 Removal and replacement ENWW...

  • Page 413: Output Bin Solenoid

    Output bin solenoid Before proceeding, remove the following components: Stapling mailbox rear cover. See Stapling mailbox rear cover on page 334. ● Remove the output bin solenoid Disconnect one connector (callout 1), remove one screw (callout 2), disconnect the solenoid arm ▲...

  • Page 414

    Chapter 2 Removal and replacement ENWW...

  • Page 415: Solve Problems

    Solve problems To use the information in this chapter, you need to have a basic understanding of the HP LaserJet printing process. Explanations of each mechanical assembly, the printer systems, and the basic theory of operation are contained in the English-only service manual. Do not perform any of these troubleshooting processes unless you understand the function of each product component.

  • Page 416: Solve Problems Checklist

    Configuration pages on page 462. If the product is connected to a network, an HP Jetdirect page also prints. If the pages do not print, check that at least one tray contains paper. If the page jams in the product, see Clear jams on page 581.

  • Page 417

    Verify that you have installed the printer driver for this product. Check the program to make sure that you are using the printer driver for this product. Print a short document from a different program that has worked in the past. If this solution works, then the problem is with the program you are using.

  • Page 418: Administration Menu Map

    Administration Menu Map Administration Menu Map report presents the entire structure of the Administration menu so you can identify how to navigate to any option. From the Home screen, scroll to and touch the Administration button. Open the following menus: Reports ●...

  • Page 419: Troubleshooting Process, Determine The Problem Source

    Troubleshooting process Determine the problem source When the product malfunctions or encounters an unexpected situation, the product control panel alerts you to the situation. This section contains a pre-troubleshooting checklist to filter out many possible causes of the problem. A troubleshooting flowchart helps you diagnose the root cause of the problem. The remainder of this chapter provides steps for correcting problems.

  • Page 420

    If so, allow the product to sit at room temperature for one to two hours. Miscellaneous Check for and remove any non-HP components (print ● cartridges, memory modules, and EIO cards) from the product.

  • Page 421: Troubleshooting Flowchart

    Troubleshooting flowchart This flowchart highlights the general processes that you can follow to quickly isolate and solve product hardware problems. Each row depicts a major troubleshooting step. A “yes” answer to a question allows you to proceed to the next major step. A “no” answer indicates that additional testing is needed. Proceed to the appropriate section in this chapter, and follow the instructions there.

  • Page 422: Power Subsystem

    Make sure that the formatter is seated and operating correctly. Turn off the product and remove the formatter. Reinstall the formatter, and then verify that the heartbeat LED is flashing. Remove any HP Jetdirect or other EIO cards, and then try to turn the product on again. NOTE:...

  • Page 423

    8 seconds: HP circle logo (without trademark symbol) appears ● 15 seconds: Fans reach full speed ● 18 seconds: HP logo (with trademark symbol) and progress bar appear; stage 1 of 8 begins ● 21 seconds: Stage 2 of 8 begins; warning not to unplug product appears ●...

  • Page 424: Control-panel Checks

    Control-panel checks The product includes a diagnostic test mode for the control panel. This mode allows you to troubleshoot issues with the touchscreen, keypad, LEDs and speaker. Start diagnostic mode Press and hold the asterisk button (*) and the plus sign (+) key at the same time. Press the Start button to initiate diagnostic mode.

  • Page 425: Scanning Subsystem

    Scanning subsystem Calibrate the scanner Use this procedure to properly position the copied image on the page. TIP: This adjustment might be required after the scanner or document feeder are replaced. Touch the Device Maintenance button. Touch the Calibrate/Cleaning button. Touch the Calibrate Scanner button, and then follow the instructions provided on the screen.

  • Page 426: Tools For Troubleshooting, Component Diagnostics, Led Diagnostics

    Heartbeat LED HP Jetdirect LEDs The embedded HP Jetdirect print server has two LEDs. The yellow LED indicates network activity, and the green LED indicates the link status. A blinking yellow LED indicates network traffic. If the green LED is off, a link has failed.

  • Page 427: Engine Diagnostics

    LED pulses on and off. Engine diagnostics This section provides an overview of the engine diagnostics that are available in the HP Color LaserJet Enterprise CM4540 MFP Series product. The product contains extensive internal diagnostics that help in troubleshooting print quality, paper path, noise, component, and timing issues.

  • Page 428: Disable Cartridge Check

    Insert a folded piece of paper into each slot to defeat the front and right door interlock switches. Figure 3-2 Diagnostic test (2 of 2) Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (.375 in) strip with a bend at the end, and insert the strip into the opening at the front of the product to defeat the front door logic switch.

  • Page 429

    horizontal lines in the primary colors (CYMK). The test page can use only Tray 2 as the paper source, so make sure that paper is loaded in Tray 2. Figure 3-3 Engine-test button The test functions differently depending on the presence of the formatter or stapler/stacker. Engine test with the formatter and the stapler/stacker removed Turn on the product, wait 30 seconds, and then press the test button.

  • Page 430: Manual Sensor Test

    Paper-path test This diagnostic test generates one or more test pages that you can use to isolate the cause of jams. To isolate a problem, specify which input tray to use, specify whether to use the duplex path, and specify the number of copies to print. Multiple copies can be printed to help isolate intermittent problems.

  • Page 431

    Table 3-3 Manual sensor diagnostic tests (continued) Sensor or switch name Sensor or switch number Sensor or switch test Duplexer refeed sensor SR22 Duplexer refeed sensor on page 386. Developer alienation sensor SR11 Developer alienation sensor on page 388. NOTE: The Developer alienation sensor can not be manually actuated.

  • Page 432: Front-door Switch

    Front-door switch Open the front-door assembly to disengage the front-door switch. Figure 3-5 Test the front-door switch Close the front-door assembly, and then check the control panel on the product for sensor response. TIP: You can leave the front door open and use a slender blade screw driver or pencil to activate the switch.

  • Page 433: Right-door Switch

    Right-door switch Open the right-door assembly to disengage the right-door switch. Figure 3-6 Test the right door switch Close the right-door assembly, or use your finger to depress the switch flag, and check the control panel on the product for sensor response. If there is no response, replace the right-door switch.

  • Page 434: Registration Sensor

    Registration sensor Open the right door. Insert a piece of paper to activate the registration sensor. Figure 3-7 Test the TOP sensor (1 of 2) NOTE: Open the registration shutter to verify the paper activates the sensor. Figure 3-8 Test the TOP sensor (2 of 2) Check the control-panel display for sensor response.

  • Page 435: Fuser Loop 1 And 2 Sensors

    Fuser loop 1 and 2 sensors Figure 3-9 Fuser loop 1 and 2 sensors location Open the right door. Lower the secondary transfer assembly. Slowly insert a piece of paper at the entrance of the fuser to activate the fuser loop sensors underneath the fuser.

  • Page 436: Fuser Output Sensor

    Fuser output sensor Figure 3-11 Fuser output sensor flag location Open the right-door assembly. Lower the secondary transfer assembly. Remove the fuser, and then verify that the sensor flag on the fuser moves freely. If the sensor flag Fuser on page 112.

  • Page 437

    Insert a piece of paper to activate the fuser output sensor. Figure 3-13 Test the fuser output sensor (2 of 2) Check the control-panel display for a sensor response. If there is no response, replace the fuser output sensor. Tools for troubleshooting ENWW...

  • Page 438: Duplexer Refeed Sensor

    Duplexer refeed sensor Open the right door. Lift the secondary-transfer assembly. Press the flag to activate the sensor. NOTE: The sensor and sensor flag are located on the back side of the registration assembly. Figure 3-14 Test the duplexer refeed sensor Check the control-panel display for sensor response.

  • Page 439: Iptu-bin-full Sensor

    IPTU-bin-full sensor NOTE: The IPTU-bin-full sensor is used only when the output tray is present. If the optional stapler/ stacker is installed, the IPTU-bin-full sensor is not used. Lift the scanner. Figure 3-15 Test the IPTU-bin-full sensor Move the IPTU-bin-full sensor flag in the output tray to activate the sensor. Check the control-panel display for sensor response.

  • Page 440: Developer Alienation Sensor

    Developer alienation sensor This sensor is located inside the main-drive assembly and cannot be accessed for direct manual testing. To test this sensor, do the following. Access the manual-sensor test menu and select sensor test SR11. Locate the in-line connector J87. Disconnect, and the reconnect the connector. The sensor indicator on the control-panel display should indicate that the sensor changed state.

  • Page 441: Fuser Pressure-release Sensor

    Fuser pressure-release sensor Open the right-door assembly. Lower the secondary transfer assembly. Remove the fuser. Insert a piece of paper to activate the fuser pressure-release sensor. Figure 3-17 Test the fuser pressure-release sensor Check the control-panel display for sensor response. If there is no response, replace fuser pressure-release sensor.

  • Page 442: Itb Alienation Sensor

    ITB alienation sensor NOTE: The document feeder, scanner, and IPTU have been removed for clarity. Open the right-door assembly. Lower the secondary transfer assembly, and then remove the fuser and ITB. Rotate the gear (callout 1) to move the flag (callout 2). If the flag does not move, replace the ITB. Figure 3-18 Test the ITB alienation sensor (1 of 4) Figure 3-19...

  • Page 443

    From inside the ITB cavity, press up on the primary-transfer-roller-disengagement flag to activate the sensor. Figure 3-20 Test the ITB alienation sensor (3 of 4) Check the control-panel display for sensor response. If there is no response, verify that the flag is moving. NOTE: Figure shows the sensor with the IPTU removed.

  • Page 444: Iptu Feed Sensor

    IPTU feed sensor Figure 3-22 IPTU feed sensor test Lift the scanner. Activate the sensor. Check the control-panel display for sensor response. If the test fails, replace the IPTU. Scanner open sensor Open the scanner and locate the sensor. Use a folded piece of paper to actuate the sensor and watch the control-panel display for a response.

  • Page 445: Tray/bin Manual Sensor Test

    Tray/Bin manual sensor test Use this test to test paper-path sensors and the paper-size switches manually. The following illustrations and table show the locations of these sensors. Scroll to and touch the Administration button. Touch the Troubleshooting button, and then touch the Diagnostic Tests button.

  • Page 446

    Table 3-4 Tray/bin manual sensor test (continued) Sensor or switch name Sensor or switch number Sensor or switch test Tray 5 paper size 1 sensor SW4 (paper feeder) Tray 5 paper size switches on page 405. Tray 5 paper size 2 Tray 5 paper size 3 Output bin full sensor The following items cannot be tested using the manual sensor test.

  • Page 447: Tray 1 Paper Sensor

    Tray 1 paper sensor Open Tray 1. Toggle the Tray 1 paper-present sensor flag. Figure 3-24 Test the Tray 1 paper sensor Check the control-panel display for sensor response. If there is no response, replace the right door assembly. See Right-door assembly on page 145.

  • Page 448: Tray 2 Paper Sensor

    Tray 2 paper sensor Remove Tray 2 and locate the sensor. Figure 3-25 Tray 2 paper sensor location Toggle the Tray 2 paper-present sensor flag. Figure 3-26 Test the Tray 2 paper-present sensor Check the control-panel display for sensor response. If there is no response, replace the cassette-pickup assembly.

  • Page 449: Tray 2 Paper Surface 1 And 2 Sensors

    Tray 2 paper surface 1 and 2 sensors NOTE: Only paper surface sensor 2 can be tested. Remove the tray and locate the sensor flag. Figure 3-27 Tray 2 paper surface 1 and 2 sensors location In the tray cavity, press the tray-closed tab to release the flag, and then toggle the flag. Figure 3-28 Tray 2 paper surface 1 and 2 Check the control-panel display for sensor response.

  • Page 450: Tray 2 Paper Size Switches

    Tray 2 paper size switches NOTE: These three switches also detect cassette presence. If these switches fail, the message Tray <X> open could appear on the control-panel display. Remove the tray. From inside the tray cavity, push any of the three switches. Figure 3-29 Test the Tray 2 paper size switches Check the control-panel display for sensor response.

  • Page 451: Tray 3 Paper Sensor

    Tray 3 paper sensor Figure 3-30 Tray 3 paper sensor location Tray 2 paper sensor on page 396. Tray 3 feed sensor Remove the tray and locate the sensor. Figure 3-31 Tray 3 feed sensor location Tools for troubleshooting ENWW...

  • Page 452: Tray 3 Paper Surface 1 And 2 Sensors

    Insert a piece of paper between the rollers to activate the feed sensor. TIP: Use stiff paper when performing this test (for example a business card or index card). Figure 3-32 Test the Tray 3 feed sensor Check the control-panel display for sensor response. If no response, replace the cassette-pickup assembly.

  • Page 453: Tray 3 Paper Size Switches

    Tray 3 paper size switches Figure 3-34 Tray 3 paper size switches location Tray 2 paper size switches on page 398. Tray 4 paper sensor Figure 3-35 Tray 4 paper sensor location Tray 2 paper sensor on page 396. Tools for troubleshooting ENWW...

  • Page 454: Tray 4 Feed Sensor

    Tray 4 feed sensor Figure 3-36 Tray 4 feed sensor location Tray 3 feed sensor on page 399. Tray 4 paper surface 1 and 2 sensors Figure 3-37 Tray 4 paper surface 1 and 2 sensors location Tray 2 paper surface 1 and 2 sensors on page 397.

  • Page 455: Tray 4 Paper Size Switches

    Tray 4 paper size switches Figure 3-38 Tray 4 paper size switches location Tray 2 paper size switches on page 398. Tray 5 paper sensor Figure 3-39 Tray 5 paper sensor location Tray 2 paper sensor on page 396. Tools for troubleshooting ENWW...

  • Page 456: Tray 5 Feed Sensor

    Tray 5 feed sensor Figure 3-40 Tray 5 feed sensor location Tray 3 feed sensor on page 399. Tray 5 paper surface 1 and 2 sensors Figure 3-41 Tray 5 paper surface 1 and 2 sensors location Tray 2 paper surface 1 and 2 sensors on page 397.

  • Page 457: Tray 5 Paper Size Switches

    Tray 5 paper size switches Figure 3-42 Tray 5 paper size switches location Tray 2 paper size switches on page 398. Tools for troubleshooting ENWW...

  • Page 458: V Laser And 24v Interlock And Logic Switches (and Power Switch)

    5V laser and 24V interlock and logic switches (and power switch) Location and testing NOTE: When a door is opened, the 5V interlock switch prevents the lasers from operating (no power). When a door is opened, the 24V interlock switch prevents the motors and high-voltage power supply from operating (no power).

  • Page 459

    Open and close the doors to make sure that the interlock switches are correctly functioning. The following figures show the interlock switch positions with the front and right doors closed and open. Defeating Front-door interlock switch ● Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (. ◦...

  • Page 460

    Front-door logic switch ● Fold a stiff piece of paper, for example a business card or index card, into a 10 mm (. ◦ 375 in) strip with a bend at the end, and insert the strip into the opening at the front of the product.

  • Page 461

    Right-door logic switch ● Use masking tape to keep the switch flag depressed. ◦ TIP: You might have to use two pieces of tape to overcome the tension return spring on the flag. Tools for troubleshooting ENWW...

  • Page 462: New Itb Sensor

    New ITB sensor NOTE: This sensor cannot be tested, but you can inspect the sensor, actuator, and the flag on the ITB for damage. Remove the existing ITB. Inspect the new ITB sensor. Press the actuator on the sensor toward the black print cartridge to verify that the actuator moves.

  • Page 463

    On the new ITB, locate and inspect the new ITB flag (callout 1). TIP: The new ITB flag is only present prior to installation. To see the flag on a previously installed ITB, insert the end of a paperclip in the hole just below the handle (callout 2) and then rotate the ITB alienation gear (callout 3).

  • Page 464: Tray 3, 4, And 5 Right Door Switch

    Tray 3, 4, and 5 right door switch NOTE: There is no manual sensor test for this sensor. Open the paper feeder right door. Check the control-panel display for the Close lower right door message. If the message does not display, open the door and inspect the flag for damage (callout 1).

  • Page 465: Paper-path Sensors Test

    Paper-path sensors test This test displays the status of each paper-path sensor and allows viewing of sensor status while printing internal pages. From the Home screen, scroll to and touch the Administration button. Touch the Troubleshooting button, and then touch the Diagnostic Tests button.

  • Page 466: Scanner Tests

    Print/stop test Use this diagnostic test to isolate the cause of problems such as image-formation defects and jams within the engine. During this test you can stop the paper anywhere along the product paper path. The test can be programmed to stop printing internal pages or an external print job when the paper reaches a certain position.

  • Page 467: Scanner Sensor Tests

    Component Actions Document feeder input motor This test runs the motor in either the forward or reverse direction. If you do not hear noise when the motor is activated, replace the document feeder. See Document feeder on page 151. If the problem continues, replace the SCB. See S-PBA-SCB (SCB) on page 179.

  • Page 468: Document Feeder Paper Present Sensor

    Document feeder paper present sensor Open the jam-access cover and locate the document feeder paper present sensor. TIP: To help locate the sensor, find the black paper present flag on the rear of the cover. Figure 3-47 Document feeder paper present sensor test Use a folded piece of paper to toggle the sensor and watch the control-panel display for a response.

  • Page 469: Document Feeder Jam Cover Sensor

    Place a finger over the sensor, and then watch the control-panel display for a response. If the test fails, replace the document feeder. See Document feeder on page 151. Document feeder jam cover sensor Open the jam-access cover and locate the sensor. TIP: To help locate the sensor, find the white sensor flag on the top of the cover.

  • Page 470: Flatbed Y (length) Sensor

    Flatbed Y (length) sensor Lift the scanner and locate the sensor. Block the sensor by placing a piece of paper on the glass and watch the control-panel display for a response. Check the control-panel display for sensor response. If the test fails, replace the scanner. See Scanner assembly on page 171.

  • Page 471: Flatbed Cover Angle Sensor

    Flatbed cover angle sensor Lift the scanner and locate the sensor. NOTE: The flatbed cover angle and the flatbed cover open sensors use the same sensor assembly. The sensor changes state when the scanner is raised approximately 50 mm (2 in). Actuate the sensor by closing and then slowly opening the scanner.

  • Page 472: Flatbed Cover Sensor

    Flatbed cover sensor Open the scanner and locate the sensor. NOTE: The flatbed cover angle and the flatbed cover open sensors use the same sensor assembly. The sensor changes state when the scanner is raised approximately 150 mm (6 in). Figure 3-49 Flatbed cover sensor test Actuate the sensor and watch the control-panel display for a response.

  • Page 473: Document Feeder Registration Sensor

    Document feeder registration sensor Lift the document feeder and locate the sensor. Actuate the sensor by inserting a stiff piece of paper, like a business card, into the paper path. Check the control-panel display for sensor response. Document feeder exit sensor Lift the document feeder and locate the sensor.

  • Page 474: Component Tests

    Document feeder read sensor Lift the document feeder and locate the sensor. Actuate the sensor by inserting a stiff piece of paper, like a business card, into the paper path. Check the control-panel display for sensor response. Component tests Control-panel tests Open the following menus: Administration ●...

  • Page 475

    Each component test can be performed once or repeatedly. If you select Continuous from the drop- down menu as the repeat option, the test cycles the component on and off. This process continues for two minutes, and then the test terminates. NOTE: The front or side door interlocks must be defeated to run the component tests.