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4-242 Service Manual

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8. Remove the 550-sheet tray controller card assembly from the shield.

Table of Contents

Default Chapter3
- Table of Contents3
Notices and Safety Information17
- Laser Notice17
- Safety Information23
  - Next26
Preface26
- Navigation Buttons26
  - Go Back26
- Change History27
- Conventions28
General Information29
- Models29
- Maintenance Approach29
- Printer Configurations30
- Options and Features31
- Printer Specifications31
- Data Security Notice39
- Tools Required for Service39
- Acronyms40
Diagnostic Information41
- Troubleshooting Map41
- Paper Jams44
- Output Option Paper Jams64
- Print Quality73
ADF & Scanner Print Quality94
- Image Quality Symptoms94
- Dark Image Quality (Using ADF or Scanner)94
- Vertical Lines (Process Direction Using the ADF)95
- Spots (Using Flatbed Scanner)95
- Skew (Using ADF)97
- Media Damage (Using ADF)98
User Messages99
- User Prompts99
- User Attendance Messages (0-99)101
Service Errors108
- Printer Hardware Errors (100-199)108
- ADF and Flatbed Scanner Errors (800-899)110
- Firmware And/Or System Electronics (900-999))111
Symptoms115
- Symptom Table-Base Printer115
- Symptom Table-500-Sheet Tray Input Option115
- Symptom Table-2000-Sheet High Capacity Feeder Input Option115
Service Checks116
- XX-Printhead Error Service Check116
- XX-Motor (Fuser) Error Service Check118
- XX-Fuser Error Service Check119
- XX, 145.XX-ITU Error Service Check122
- XX-LVPS Error Service Check123
- XX-Cartridge Sensor Error Service Check124
- XX-Black Cartridge Motor Error Service Check129
- XX-Cyan Cartridge Motor Error Service Check130
- XX-Magenta Cartridge Motor Error Service Check132
- XX-Yellow Cartridge Motor Error Service Check133
- XX-Autocomp (Tray 1) Motor Error Service Check135
- XX-Staging Motor Error Service Check136
- XX-Duplex Motor Error Service Check137
- XX-Paper Path Redrive Motor Error Service Check137
- XX-ITU Motor Error Service Check139
- XX-LVPS Fan Error Service Check140
  - Next140
- XX-Main Fan Error Service Check140
- XX-Blower Fan Error Service Check141
- Paper Jam Error Service Check142
- 200.08-Paper Jam Error Service Check143
- Go Back143
- 200.07-Paper Jam Error Service Check144
- Paper Jam Error Service Check145
- 200.38-Paper Jam Error Service Check147
- 200.37-Paper Jam Error Service Check148
- Paper Jam Error Service Check149
- 200.48-Paper Jam Error Service Check151
- 200.47-Paper Jam Error Service Check152
- Paper Jam Error Service Check153
- Paper Jam Error Service Check155
- Paper Jam Error Service Check156
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check157
- Option) Service Check158
- Paper Jam (550-Sheet/2000-Sheet Input Option) Service Check160
- 250.22-MPF Motor Error Service Check162
- Media Missing Jam Service Check165
- Sensor (ADF Sheet Through) Late Jam Service Check166
- Sensor (ADF Sheet Through) Static Jam Service Check166
- Sensor (1St Scan) Static Jam Service Check168
- Sensor (ADF 1St Scan) Late Jam Service Check169
- Sensor (2Nd Scan) Lingering Jam Service Check170
- Sensor (2Nd Scan) Static Jam Service Check171
- Sensor (ADF Media Exit) Late Jam Service Check172
- 285.03, 285.07-Sensor (ADF Media Exit) Static Jam Service Check173
- Sensor (ADF Media Exit) Late Jam Service Check174
- ADF Top Door Open Jam Service Check175
- XX-HTU Input Sensor Error Service Check176
- XX-HTU Output Sensor Error Service Check177
- XX-HTU Second Sensor Error Service Check178
- XX-5-Bin Mailbox Input Sensor Error Service Check180
- XX-5-Bin Mailbox Pass Thru Sensor Error Service Check182
- Finisher/Stacker Main Motor Error Service Check184
- XX-Finisher/Stacker Sensor (Pass Thru) Error Service Check185
- 456.08-Finisher Stapler Home Sensor Error Service Check186
- X-Finisher Stapler Motor Error Service Check187
- X-Finisher/Stacker Paddle Motor Error Service Check188
- 461.08-Hole Punch Sensor Error Service Check189
- 461.32-Hole Punch Motor Error Service Check190
- Scanner Cable Service Check191
- XX-Scanner Carriage Home Position Detection Service Check192
- XX-Scanner Card Service Check194
- Scanner Flatbed Fan Service Check195
- Steps before Starting the 9Yy Service Checks196
  - Collecting the History Information from the SE Menu196
  - Collecting the Firmware Logs (Fwdebug and Logs.tar.gz) from the SE Menu196
  - Collecting the Settings from the Menu Settings Page197
Diagnostic Aids241
- Understanding the Operator Panel and Menus241
- Accessing Service Menus247
- Diagnostics Mode248
Entering the Configuration Menu269
- Next269
- Exiting the Configuration Menu270
- Reset Separator Roll and Pick Assembly Counter270
- USB Scan to Local270
- Black Only Mode270
- Print Quality Pages270
- Reports271
- Color Trapping271
- Tray Insert Msg271
- Size Sensing271
- Panel Menus271
- PPDS Emulation271
- Download Emuls271
- Factory Defaults271
- Energy Conserve272
- Fax Low Power Support272
- Min Copy Memory272
- Numpad Job Assist272
- Format Fax Storage272
- Fax Storage Location272
- Color Adjustment272
- Auto Align Adj273
- Color Alignment273
- Motor Calibration273
- ADF Edge Erase273
- FB Edge Erase273
- Scanner Manual Registration273
- Disable Scanner273
- Paper Prompts273
- Envelope Prompts274
- Action for Prompts274
- Jobs on Disk274
- Disk Encryption274
- Wipe Disk274
- Font Sharpening274
- Require Standby274
- UI Automation275
- Key Repeat Initial Delay275
- Key Repeat Rate275
- Clear Custom Status275
- USB Speed275
- Exit Config Menu275
Theory of Operation276
- Paper Path, Transport Components276
- Print Engine Theory278
- Names and Functions of Components289
  - Scanner Unit Assembly289
  - Adf290
- Printhead Verification292
- Adjustments294
Repair Information311
- Handling ESD-Sensitive Parts311
- Data Security Notice311
- Removal Procedures312
  - Cable Ties312
  - Arrangement of Removals in this Chapter312
- Base Printer Cover Removals313
Base Printer Removals343
- ACM Bias Spring Removal343
- Bin-Full Flag Removal343
- Bin-Full Sensor Removal344
- Cartridge Blower Assembly Removal345
- Cartridge Contact Block Assembly Removal348
- Cartridge Memory Block Removal350
- Cartridge Metering Cable Removal352
- Cartridge Rail Removal354
- CPU Cooling Fan Removal356
- Datum Bell Crank Removal358
- Duplex Assembly Removal360
- ESD Bracket Removal362
- EP Drive Assembly Removal364
- Exit Cooling Duct Removal366
- Front Access Door Beacon Removal367
- Front USB Cable Removal369
- Fuser Assembly Removal370
- Fuser Drive Assembly Removal371
- Fuser System Card and LVPS Cable Removal373
- Fuser Thermistor Removal376
- High-Voltage Power Supply (HVPS) Board Removal377
- Housing Interlock Assembly Removal381
- ITU Assembly Removal382
- ITU Autoconnect Removal383
- ITU Block Assembly Removal385
- Left Access Door Piston Removal387
- Low-Voltage Power Supply (LVPS) Removal391
- LVPS Exit Duct Removal394
- LVPS Fan Removal395
- Main Fan Removal398
- Media Tray Rail Removal399
- MPF Breakaway Assemblies Removal405
- MPF Paper Pick Assembly Removal (Including the MPF Ratchet Collar and MPF Drive Pulley)408
- MPF Pick Rolls and Special Wear Strip Removal411
- MPF Drive Assembly Removal414
- MPF Sensor Plate Assembly Removal416
- MPF Wear Strips Removal417
- Operator (OP) Panel Assembly Removal417
- OP Panel Cables Removal420
- OP Panel Display Removal421
- OP Panel Housing Removal422
- OP Panel Speaker Removal423
- OP Panel UICC Card Removal423
- Pad Removal424
- Paper Auto-Size Sensor Removal425
- Paper Path Redrive Assembly with Sensors Removal426
- Paper Pick Mechanism Assembly Removal428
- Pick Rolls Removal430
- Printhead Removal, Installation, and Alignment431
  - Installing and Coarse Aligning the Printhead433
  - Aligning the Printhead437
  - Dual Diode Alignment437
  - Registration (Black)438
  - Color Alignment (Cyan, Yellow, and Magenta)439
- Redrive Gears Removal442
- Redrive Motor Removal443
- Sensor (D1, D2, and Fuser Bubble) Removal445
- Sensor (Input, S1, Narrow Media, Near Narrow Media) Removal447
- Staging Deflector Assembly Removal448
- Staging Paper Path Reference Edge Assembly Removal450
  - Staging Paper Path Reference Edge Adjustment455
  - Aligning the Staging Paper Path Reference Edge455
- Standard Media Tray Removal458
- System Board Removal459
- System Board Cage with Board Removal467
- Waste Toner Container Removal473
- Waste Toner Gears Removal473
- Waste Toner Sensor Removal474
- Waste Toner Cable Removal475
- Waste Toner Full Cable Removal477
- Waste Toner Full Sensor Removal478
- Waste Toner Tray Bracket Removal478
ADF Cover Removals480
- ADF Front Cover Removal480
- ADF Rear Cover Removal481
- ADF Top Door Assembly Removal481
ADF Removals483
- ADF Beacon Cable Removal483
- ADF Controller Card Removal484
- ADF Document Tray Assembly Removal484
- ADF Document Tray Extension Removal485
- ADF Duplex CCD Assembly Removal486
- ADF Duplex CCD Scan Glass Assembly Removal489
- ADF Feed 1-Way Bearing and Gears Removal490
- ADF Feed Drive Motor Assembly Removal490
- ADF Feed/Pick Roll Assembly Removal493
- ADF Left Hinge Removal494
- ADF Lower Door Assembly Removal495
- ADF Media Pinch Pad Assembly Removal496
- ADF Pick Pad Cover Assembly Removal498
- ADF Pick Roll Position Cam Assembly Removal499
- ADF Pinch Roll Assembly Removal502
- ADF Platen Cushion Removal503
- ADF Right Hinge Removal504
- ADF Separator Roll Removal504
- ADF Separator Torque Limiter Assembly Removal505
- ADF Solenoid Assembly Removal506
- ADF Transport Drive Gears (Front) Removal507
- ADF Transport Drive Gears (Rear) and Pulley Removal509
- ADF Transport Drive Motor Bracket Assembly with Cable Removal510
- ADF Turn Guide Removal512
- ADF Unit Assembly Removal513
- Sensor (ADF 1St Scan) Removal515
- Sensor (ADF 2Nd Scan) Removal515
- Sensor (ADF Document Set) Removal516
- Sensor (ADF Lower Door Interlock) Removal517
- Sensor (ADF Media Exit) Fan Bracket Assembly Removal518
- Sensor (ADF Sheet Through) Removal519
- Sensor (ADF Top Door Interlock) Removal519
- Switch (ADF Closed Interlock) Removal520
Scanner Cover Removals521
- AIO Rear Scanner Cover Removal521
- AIO Lower Scanner Cover Removal522
- Scanner Front Cover Removal523
- Scanner Left Side Front Cover Removal524
- Scanner Left Side Rear Cover Removal524
- Scanner Rear Cover Removal525
- Scanner Right Side Cover Removal525
- Scanner Top Cover Removal526
Scanner Removals527
- Carriage Belt Tensioner Assembly Removal527
- Carriage Drive Motor Assembly Removal528
- Flatbed Scanner Cooling Fan Filter Removal530
- Flatbed Scanner Cooling Fan Removal530
- Flatbed Scanner CCD Assembly Removal531
- Scanner Exposure Lamp Removal532
- Scanner FB Length Sensor Cable Removal534
- Flatbed Scanner Assembly Removal536
- Scanner Interface Card Removal543
- Scanner Platen Glass Cover Removal544
- Scanner Reference LED Removal545
- Scanner Reference LED Sensor Cable Removal545
- Sensor (Platen Glass Length) Removal546
- Sensor Cable (Scanner HP) Removal547
- Sensor (Scanner HP) Removal548
Input Option Removals549
550-Sheet Tray549
- 550-Sheet Drawer Assembly Removal549
- 550-Sheet Media Tray Assembly Removal550
- 550-Sheet Tray Controller Card Assembly Removal551
- 550-Sheet Tray Deflector Removal553
- 550-Sheet Tray Drive Assembly Removal554
- 550-Sheet Tray Left Anti-Tip Latch Removal557
- 550-Sheet Tray Pass Thru Sensor Removal559
- 550-Sheet Tray Pick Assembly Removal560
- 550-Sheet Tray Pick Roll Assembly Removal564
- 550-Sheet Tray Right Anti-Tip Latch Assembly Removal566
- 550-Sheet Tray Top Metal Cover Removal567
2000-Sheet High-Capacity Feeder568
- 2000-Sheet High-Capacity Feeder Bellcrank Assembly Removal569
- 2000-Sheet High-Capacity Feeder Controller Card Assembly Removal570
- 2000-Sheet High-Capacity Feeder Drive Assembly Removal571
- 2000-Sheet High-Capacity Feeder Elevator Home Sensor Removal574
- 2000-Sheet High-Capacity Feeder Jam Clearance Cover Removal578
- 2000-Sheet High-Capacity Feeder Jam Clearance Top Cover Removal583
- 2000-Sheet High-Capacity Feeder Jam Door Clearance Sensor Removal584
- 2000-Sheet High-Capacity Feeder LED Bracket Removal587
- 2000-Sheet High-Capacity Feeder Left Anti-Tip Latch Assembly Removal588
- 2000-Sheet High-Capacity Feeder Left Side Cover Removal590
- 2000-Sheet High-Capacity Feeder Lift Drive Gear Assembly Removal592
- 2000-Sheet High-Capacity Feeder Lift Drive Motor Assembly Removal599
- 2000-Sheet High-Capacity Feeder Media Tray Assembly Removal602
- 2000-Sheet High-Capacity Feeder Pass Thru Sensor Removal603
- 2000-Sheet High-Capacity Feeder Pick Assembly Removal605
- 2000-Sheet High-Capacity Feeder Pick Roll Assembly Removal611
- 2000-Sheet High-Capacity Feeder Rear Cover Removal614
- 2000-Sheet High-Capacity Feeder Right Anti-Tip Latch Assembly Removal616
- 2000-Sheet High-Capacity Feeder Right Side Cover Removal618
Output Option Removals620
5-Bin Mailbox620
- 5-Bin Mailbox Access Door Removal620
- 5-Bin Mailbox Backup Roll Plate Assembly Removal622
- 5-Bin Mailbox Bin-Full Beacon Card and Light Pipe Removal623
- 5-Bin Mailbox Cave Beacon Removal624
- 5-Bin Mailbox Controller Card Removal625
- 5-Bin Mailbox Diverter Solenoid Removal626
- 5-Bin Mailbox Diverter Spring Removal627
- 5-Bin Mailbox Feed Motor with Plate Removal628
- 5-Bin Mailbox Front Cover Removal629
- 5-Bin Mailbox Media bin Full Actuator Removal631
- 5-Bin Mailbox Option Cable Removal632
- 5-Bin Mailbox Output bin Deflector Removal633
- 5-Bin Mailbox Output bin Paper Bail Removal634
- 5-Bin Mailbox Output bin Roller Removal635
- 5-Bin Mailbox Output bin Sensors Removal635
- 5-Bin Mailbox Paper Jam Beacon Removal636
- 5-Bin Mailbox Rear Cover Removal637
- 5-Bin Mailbox Roller Removal638
- 5-Bin Mailbox Sensor (Input) Assembly Removal639
- 5-Bin Mailbox Sensor (Pass Thru) Assembly Removal639
- 5-Bin Mailbox Top Cover Removal640
- 5-Bin Mailbox Tray Extension Removal641
Staplesmart Finisher and High-Capacity Output Stacker642
- Finisher or Stacker Access Door Beacon LED and Beacon Housing Removal642
- Finisher or Stacker Bin-Full Spring Removal643
- Finisher or Stacker Bottom Cover Removal644
- Finisher or Stacker Controller Card Assembly Removal645
- Finisher or Stacker Feed Roller Removal646
- Finisher or Stacker Front Cover Removal647
- Finisher or Stacker LED Sensor Cover Removal648
- Finisher or Stacker Left Access Door Assembly Removal649
- Finisher or Stacker Media Stack Flap and Media Stack Flap Actuator Removal651
- Finisher or Stacker Option Cable Removal652
- Finisher or Stacker Output bin Extension Removal653
- Finisher or Stacker Output bin LED and LED Lens Removal653
- Finisher or Stacker Paddle Drive Gear Removal654
- Finisher or Stacker Paddle Drive Motor Assembly Removal655
- Finisher or Stacker Rear Cover Removal656
- Finisher or Stacker Sensor (Bin-Full Receive) Removal658
- Finisher or Stacker Sensor (Bin-Full Send) Removal659
- Finisher or Stacker Sensor (Finisher bin Media Present) Removal660
- Finisher or Stacker Sensor (Paddle HP) Removal661
- Finisher Sensor (Stapler Access Door Interlock) Removal662
- Finisher or Stacker Sensor (Pass Thru) Removal662
- Finisher or Stacker Sensor (Tamper HP Left and Right) Removal664
- Finisher or Stacker Standard Output bin LED and LED Lens Removal665
- Finisher or Stacker Tamper Drive Belt Removal666
- Finisher or Stacker Tamper Drive Motor Assembly Removal667
- Finisher or Stacker Tamper Recoil Spring Removal668
- Finisher or Stacker Top Cover Removal669
- Finisher Stapler Unit Assembly Removal670
Horizontal Transport Unit (HTU) and Hole Punch Unit671
- HTU Access Door Removal671
- HTU Access Door Paper Jam Beacon (with Cover and Cable) Removal672
- HTU Access Door Rollers Removal673
- HTU bin Diverter Gate Spring Removal675
- HTU bin Media Exit Spring Removal676
- HTU Card (Bin-Full Receive Card and Lens) Removal677
- HTU Card (Bin-Full Send Card and Lens) Removal678
- HTU Controller Card Removal679
- HTU Drive Belt Removal680
- HTU Drive Gear Spring Removal681
- HTU Engagement Roller Removal682
- HTU Exit Roller Removal683
- HTU Front Redrive Cover Removal683
- HTU Front Standard bin Cover Removal684
- HTU Locking Lever Removal685
- HTU Locking Lever Card Removal687
- HTU Lower Redrive Guide Removal687
- HTU Option Hook Removal690
- HTU Option Roller Removal692
- HTU Output bin Removal693
- HTU Output bin Extension Removal694
- HTU Output bin Solenoid Removal695
- HTU Output bin Wire Stop Removal696
- HTU Output Option Removal697
- HTU Output Option Guide Removal699
- HTU Output Option Solenoid Removal700
- HTU Output Sensor Removal701
- HTU Outer Front Cover Removal (AIO Only)701
- HTU Rear Redrive Cover Removal702
- HTU Rear Standard bin Cover Removal704
- HTU Right Bottom Cover Removal707
- HTU Right Inner Cover Removal708
  - HTU Sensor (Access Door Interlock) Removal712
  - HTU Sensor (Empty Bin) Removal713
  - HTU Sensor (Input) Removal714
  - HTU Sensor (Output Option Position) Removal715
  - HTU Sensor (Second) Removal716
  - HTU Sensor Cable (Bin-Full Send and Receive) Removal717
  - HTU Stopper Diverter Removal717
  - HTU Timing Belts (Rear) Removal718
  - HTU to Printer Cable Removal719
  - HTU Top Redrive Cover Removal720
  - HTU Top Right Cover Removal721
  - HTU Transport Gear Removal722
  - HTU Transport Motor Removal723
  - HTU Upper Exit Shaft Removal724
  - HTU Upper Guide Removal725
  - HTU Punch Motor Removal726
  - HTU Punch Unit Removal728
  - HTU Punch Gear Removal729
Connector Locations731
- Locations731
  - System Board Cabling Reference731
- Connectors732
Preventive Maintenance755
- Safety Inspection Guide755
- Individual Maintenance Part Expected Life755
- Lubrication Specifications756
- Lubrication for Replacement Motors756
  - Redrive Parts Packet756
  - Fuser Drive Assembly757
Parts Catalog759
- How to Use this Parts Catalog759
- Assembly 1: Front, Right, and Top Covers760
- Assembly 2: Left and Rear Covers762
- Assembly 3: Front764
- Assembly 3.1: Front (Continued)766
- Assembly 4: Left768
- Assembly 4.1: Left (Continued)770
- Assembly 5: Rear772
- Assembly 6: Flatbed Scanner776
- Assembly 7: ADF Unit Assembly778
- Assembly 8: ADF Covers780
- Assembly 9: ADF Feed and Drive782
- Assembly 10: ADF Electronics784
- Assembly 11: Optional 550-Sheet Tray786
- Assembly 12: Optional 550-Sheet Drawer Assembly788
- Assembly 13: Optional 2000-Sheet High-Capacity Feeder (Complete)790
- Assembly 14: Optional 2000-Sheet High-Capacity Feeder792
- Assembly 15: Finisher/High-Capacity Ouput Stacker Assembly794
- Assembly 15.1: Finisher /High-Capacity Output Stacker Assembly (Continued)796
- Assembly 16: Finisher Stapler Assembly798
- Assembly 17: Finisher/Stacker Assembly (Complete)800
- Assembly 18: 5-Bin Mailbox Assembly (Complete)802
- Assembly 19: 5-Bin Mailbox Assembly (Covers)804
- Assembly 20: 5-Bin Mailbox Assembly (Interior)806
- Assembly 21: HTU (Complete)808
- Assembly 22: HTU (Covers)810
- Assembly 23: HTU (Left Interior)812
- Assembly 24: HTU (Right Interior)814
- Assembly 25: HTU with Hole Punch (Complete)816
- Assembly 26: HTU with Hole Punch (Covers)818
- Assembly 27: HTU with Hole Punch (Left Interior)820
- Assembly 28: Miscellaneous822
- Assembly 29: Internal Options824
- Cable and Thermistor Location Table825
- Screw and Retainer Identification Table829
Appendix A-Print Samples835
- Print Tests835
- Registration and Alignment840
Index845
Part Number Index853

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